COMPONENTS AND REPAIR MANUAL AIR MANUAL
COMPONENTS AND REP AIR MANUAL REPAIR 2006 Perimeter Rd. Greenville, SC 29605 Toll Free: 800-435-9340 - Phone: 864-277-5870 Fax: 864-235-9661 - www.mightymole.com email: [email protected]
MODEL MCL 42 HD EARTH BORING MACHINE MACHINE SERIAL NO.: 3642HD05040604 & LA TER LATER MANUAL
PART
NO.:
E250400
Machine Serial #_________________________________________________________ Purchased & Serviced Thru: __________________________________________________________ Purchase Date: _________________________________________________________ © 2003 by McLaughlin Group, Inc.
All rights reserved. No part of this manual may be reproduced in any form or by any means without prior written permission from McLaughlin Group, Inc.
Revision Date: DEC 2006
WARNING: Battery posts, terminals and releated accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
WARNING:
The engine exhaust from this product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
TABLE OF CONTENTS McL 42 HD
DESCRIPTION
PAGE
Machine Specifications and System Operating Specifications
1.1.0
Fill Points, Filters and Routine Maintenance Decal Placement
2.1.0 2.2.0
Machine Assemblies, Parts Details Jacking Station Assembly Carriage Assembly Roll Bar Assembly Powertrain Assembly Dog Plate Assembly Casing Pusher Assemblies & Adapters Track Assembly Hydraulic Tank Assembly Fuel Tank Assembly
3.0 3.1.0 3.2.0 3.3.0 3.4.0 3.5.0 3.6.0 3.7.0 3.8.0 3.9.0
Machine Operating Systems Hydraulic System (Hoses and Fittings) Electrical System (Wiring Diagram)
4.0 4.1.0 4.2.0
Machine Component Parts Details Engine (Operation and Parts) Gearbox (Parts) Transmission (Parts) Hydraulic Pump Coupling Hydraulic Clutch Hydraulic Thrust Cylinder Hydraulic Dog Plate Cylinder Hydraulic Valve (Parts)
5.0 5.1.0 5.2.0 5.3.0 5.4.0 5.5.0 5.6.0 5.7.0 5.8.0
Hydraulic Clutch Operation Troubleshooting
6.0 6.1.0 6.2.0
McLaughlin Group, Inc. reserves the right to make changes at any time without notice or obligation.
TABLE OF CONTENTS McL 42 HD
DESCRIPTION
PAGE
Service and Repair Instructions Machine Split Coupling (Transmission/Gearbox) Hydraulic Pump Coupling Dog Plate Cylinder Hydraulic Clutch Pump Settings and Adjustments Main Thrust Valve
7.0 7.1.0 7.2.0 7.3.0 7.4.0 7.5.0 7.6.0 7.7.0 7.8.0
Deutz Emission Warranties
Insert
McLaughlin Group, Inc. reserves the right to make changes at any time without notice or obligation.
MACHINE SPECIFICATIONS McL 42 HD
SPECIFICA TIONS OF MCL 42 HD SPECIFICATIONS EARTH BORING MACHINE Boring Range:
ENGLISH
METRIC
Cased Bore
16”-42”
41 cm-107 cm
Engine: Air cooled, in-line 4 cylinder diesel, turbo charged 12 VDC electric system 106 hp ISO max. (79 kW) @ 2,500 RPM 96 hp continuous (72 kW) @ 2,500 RPM
Transmission: 5 forward speeds, 1 reverse Clutch: Hydraulic clutch with Operator Presence Control Switch Final Drive: Planetary reduction, 4” hex chuck (10 cm) Auger Torque: 113,500 ft/lbs. peak(153,900 Nm) in 1st gear Forward Thrust: 633,333 lbs. (2817 kN) max @ 5,000 psi (345 bar) with infinitely adjustable thrust speed
Dog Plate: Hydraulically activated with dog pin indicators Hydraulic Parameters: 5,000 psi (345 bar) max. system, pressure comp. pump with load sense, 48 gpm (182) lpm @ 2,500 RPM, hydraulic tank capacity 52 gallons (198 L), oil level sight gauge, temp. and cleanout ports.
Hydraulic Filtration:
1. Suction strainer - 100 mesh 2. In-take return filter - 12 micron replaceable element 3. 10 micron spin-on return filter
Fuel Tank: 11 gallon (41.5 L) capacity with sight gauge
Dimensions/Weights Machine: 68” (173 cm) wide x 12’ ( 3.6 m) long x 68” (173 cm) high Jacking Station: 5,200 lbs. (2,360 kg) Carriage: 6,650 lbs. (3,017 kg) Casing Pusher: 1,150 lbs. (522 kg)
Track: 60 1/2” (154 cm) wide x 9’ (274 cm) long x 14.5” (37 cm) high - 1,400 lbs.(635 kg) 5’ (152 cm)Track Extension: 750 lbs. (341 kg) Machine Centerline: 29 3/8” (75 cm) Push Plate: 440 lbs. (200 kg) McLaughlin Group, Inc. reserves the right to make changes at any time without notice or obligation.
1.1.1
SYSTEM OPERATION SPECIFICATIONS McL 42 HD
Engine 1. Speed 2. Oil 3. Fuel 4. Fuel Tank Capacity
Idle: 1050-1150 Max.: 2400-2500 SAE 5W-30 or refer to Engine Manual Commercially available diesel fuel with less than 0.5% sulphur content. Refer to Engine Manual. ~ 15 Gallons (56 l.)
Gearbox Capacity
80-90 wt. gear oil with EP additives ~ 2 Gallons (8 l.)
Transmission Capacity
Synthetic 50 wt. transmission fluid 1.5 Gallons (5.9 l)
Hydraulic System 1 Hydraulic Pump 2. Hydraulic Control Valve Main Thrust Sysem
Pressure Compensated w/ Load Sense Compensator Setting: ~ 5000 psi Stand-by Setting: ~ 250-300 psi Electric-proportional w/ Manual operation Relief Valve Setting: ~ 5100 + psi
3. Hydraulic Track Brake (Secondary System)
Setting: ~ 800 psi
4. Hydraulic Dog Pins (Secondary System)
Setting: ~ 800 psi
5. Hydraulic Clutch (Secondary System)
Setting: 225 psi
6. Hydraulic Fluid:
76 Unax AW #46 or equivalent ISO grade 46, hydraulic fluid with anti-wear additives. Contains additives that provide oxidation resistance, rust and corrosion protection, foaming resistance and have water separating characteristics. Consult McLaughlin Group, Inc. for recommendations on cold weather operation.
7. Hydraulic Tank Capacity
~ 50 Gallons (189 l.)
Electrical System 1. Battery 2. Hydraulic Control Valve Main Thrust System 3. Preheat System 4. Fuses 5. Cartridge Valves
12V DC w/ 700 CCA Max. 12V DC w/ Valve Driver Card and Potentiometer .6 Amps to shift valve, 1.8 Amps to shift fully 12 V DC w/ manual delay 12V DC, Inline and panel, SFE and ATO styles 12V DC at 1-3 Amps
*Specifications subject to change without notice or obligations.
1.1.2
FILTERS AND FILL POINTS McL 42 HD
1
1. Engine Oil Fill - Use only manufacturer’s approved oils (Reference section 5.1 Engine Operation).
2
2. Dip Stick - Check daily with engine warm. Fill as needed to the upper dash mark on the stick.
3. Oil Filter - Use only manufacturer approved engine filter. Reference section 5.1 Engine Operations for specifications and maintenance.
3, 4
4. Fuel Filter - Use only manufacturer’s approved replacement filters. (Reference section 5.1 Engine Operation for maintenence schedule).
5
5. Fuel Level - Fill as needed with branded grades of diesel fuel with a sulfur content below 0.5% (Reference section 5.1co Engine Operation for approved fuel specifications).
2.1.1
FILTERS AND FILL POINTS McL 42 HD
6
6. Hydraulic Oil Level - Fill to 1 1/2” below top of tank (with cylinders retracted). Change oil after first 1000 hours of use, then annually.
7
7. Hydraulic Oil Filter - Replace all filters with every engine oil change or if required by filter indicator, whichever comes first. Clean or replace in-tank suction strainer annually when oil is changed.
8. Gearbox Oil Fill - Fill to check point. Change after first 50 hours of use, then every 1000 hours or annually.
8
9. Transmission Oil Fill - Fill to check point with #50 synthetic transmission fluid. Change after first 50 hours of use, then every 1000 hours or annually.
9 10. Engine Air Cleaner - Check air cleaner element condition using the filter indicator. Clean or replace element when indicator is in the “red zone.” Clean or replace when required by the filter indicator or annually, which ever comes first. Reference pages 5.1.23 & 5.1.24 of the Engine Operation section for more information.
2.1.2
DECAL APPLICATION: REMOVE OIL AND DIRT FROM SURFACE. MAKE SURE SURFACE IS SMOOTH.
2.2.1
PLACE ON MANUAL BOX
J800030 - INSTRUCTION OPERATOR’S MANUAL
J000080 - WARNING DO NOT GO FORWARD
J000020 - WARNING AVOID DEATH
J000210 - WARNING LOCATE UTILITIES
J000100 - DANGER ENTANGLEMENT HAZARD
DECAL PLACEMENT McL 42 HD
2.2.2
J000080 - WARNING DO NOT GO FORWARD
J000200 - DANGER MACHINE PARTS
J000120 - DANGER ROTATING BLADES
J802000 - WARNING ROTATING SHAFT
J000160 - CAUTION PINCH POINT 2 REQUIRED
DECAL PLACEMENT McL 42 HD
JACKING STATION ASSEMBLY McL 42 HD
3.1.1
JACKING STATION ASSEMBLY McL 42 HD
ITEM# 1 2
3
4
5
6
7
QTY. 1 4 4 4 4 8 8 4 4 4 1 1 1 4 4 1 2 1 1 4 4 4 4 4 1 4 4 4 1
NUMBER 4210101 4810129 4810134 U001583 4810130 4800147 U340065 W000100 U001581 U210071 4801110 4801111 4801113 U210100 U000820 4801112 U000080 W200215 4801114 U210060 U000420 4800149 4810134 U001583** 4210130 U000440 U200600 U210060 E 250210
DESCRIPTION Jacking Station Anchor Pin Heavy Duty Washer Screw, HC 1-8 x 6.50 G8** Hold Down Hold Down Pin .25" Linch Pin Cam Roller Screw, HC 1.25-7 X 5.50 ZP Nut, Lock NY 1.25-7 Track Brake Assembly Track Brake Cylinder Carrier Mounting Block Washer, Lock .500 Screw, HC .500-13 X 1.25 G5 Piston Screw, HC .250-20 X 1.25 G5 O-Ring #236 Stop Plate Washer, Lock .375 Screw, HC .375-16 X 1.00 Carriage Pin 1/2' Heavy Duty Washer Screw, HC 1-8 X 6.50 G8 Quick Disconnect Mount Screw, HC .375-16 X 1.25 G5 Washer, Flat .375 Washer, Lock .375 Safety Manual Box (Not Shown)
** - Use exact grade specified - DO NOT change from original equipment.
3.1.2
CARRIAGE ASSEMBLY McL 42 HD
3.2.1
CARRIAGE ASSEMBLY McL 42HD
ITEM # 1 2
3
4
5
6
QTY. 1 1 4 8 1 3 6 6 1 4 4 1 2 2 2 1 1
NUMBER 4210201 4210701 4800762 U120200 4210219 4800277 U200060 U100060 4810270 U000820 U210111 4810277 U000180 U210040 U200060 X 400030 X 400020
DESCRIPTION Carriage Hydraulic Tank Hydraulic Tank Mount Nut, Hex .375-16 Fuel Tank Fuel Tank Mount Washer, Flat .375 Nut, Hex .375-16 Battery Bracket Screw, HC .500-13 X 1.25 Washer, Lock .500 Battery Hold Down Screw, HC .312-18 X .75 Washer, Lock .312 Washer, Flat .375 Battery Enclosure Battery Automotive
3.2.2
ROLL BAR ASSEMBLY McL 42 HD
3.3.1
ROLL BAR ASSEMBLY McL 42 HD
ITEM# 1
2
3
4 5
6
7
QTY. 1 16 16 16 1 12 12 12 1 4 4 4 1 1 1 1 4 8 12 8 2 4 1 4 4 4 1 1 2 2 2 1 1 1 1 1 1
NUMBER 4210230 U001420 U210160 U100200 4810232 U000860 U200100
DESCRIPTION Ro ll Cag e Scre w, HC .750-10 X 2.50 Washe r, Lo ck .750 Nut, He x .750-10 Pump Ro ll Cag e Scre w, HC .500-13 X 1.75 Washe r, Flat .500
U100120 4210250 U000820 U210100 U100120 4800288 4800299 4800298 4800297 4800290 U000817 U200100 U210100 4800295 U120200 4210264 U000040 U210020 U200020 4801300 4801301 U200040 U210040 U000160 4801333 2050057 U000220 U210040 U200040 U210041
Nut, He x .500-13 To o lb o x Scre w, HC .500-13 x 1.25 Washe r, Lo ck .500 Nut, He x .500-13 Mirro r Bracke t Mirro r Le ft Sid e Muffle r Bracke t Rig ht Sid e Muffle r Bracke t Muffle r Iso lato r Scre w, HC .500-13 X 1.00 G8 Washe r, Flat .500 Washe r, Lo ck .500 Muffle r Ho o k Nut, Whiz, Lo ck Op e rato r Co nso le Scre w, HC .250-20 X .750 Washe r, Lo ck .250 Washe r, Flat .250 Drag Brake Hand le Asse mb ly Drag Brake Hand le Bracke t Washe r, Flat .312 Washe r, Lo ck .312 Scre w, HC .312-18 X .500 Le ve r Le ve r Grip Scre w, HC .312-18 X 1.25 Washe r, Lo ck .312 Washe r, Flat .312 Nut, Nylo ck .312-18
ITEM#
QTY.
8
1 4 4 4 1 1 1 1 1 1 1 4 1 1 3 3 3
9
10
NUMBER
DESCRIPTION
4210262 U000040 U200020 U210020 4800784 4800829 X000400 3600116 3600115 3600131 4800778 U030110 4810710 4210211 U000817 U210100 U200100
Co nso le Co ve r Plate Scre w, HC .250-20 X .750 Washe r, Flat .250 Washe r, Lo ck .250 Pre ssure Gaug e , 5000 p si Po we r Outle t Tacho me te r, Op e rato r Switch Thro ttle Co ntro l Thro ttle Cab le Thro ttle Cab le Bulkhe ad Ad ap te r Co ntro l Valve Scre w, SFH .437--14 X 1.25 Valve Hand le Valve Ad ap te r Plate Scre w, HC .500-13 X 1.00 G8 Washe r, Lo ck .500 Washe r, Flat .500
Optional Equipment (Available upon request) 1
3.3.2
1
4810281
Vand al Shie ld , Co ntro l Pane l
POWERTRAIN ASSEMBLY McL 42 HD
3.4.1
HYDRAULIC PUMP DETAIL
POWERTRAIN ASSEMBLY
HYDRAULIC PUMP DETAIL
McL 42 HD
ITEM #
QTY.
NUMBER
DESCRIPTION
1 2
1 1 1 1 1 1 1 1 1 1 1 3 3 3 1 2 4 1 1 1 1 1 1 1 1 1
4210302 4800324 U001590 4801108 U024010 4800328 3600131 3600115 4800365 4800379 4800364 U000802 U210080 U100100 4800384 4800341 U120205 4800368 4800381 4810308 4800378 4210317 4200041 4210315 4210316 4800338 480033801 480033802 480033803 48100310 48100311 U001642 U001646 U210223 4800212 4800215 U001642 U210223 4800352 U001020 U000806 U200100 U120120
20 913 4 Cylind e r De utz Eng ine Thro ttle Cab le Arm Scre w, HC 8mm X 1.25 X 15mm Cab le Lo ck Scre w, Se t .250-20 X .500 KN Cup Bracke t, Cab le Bulkhe ad Bulkhe ad Ad ap te r Kit Thro ttle Cab le Shut Do wn So le no id Exhaust Se al Ring s 21 Exhaust Manifo ld Elb o w 22 Scre w, HC .438-14 X 2.250 23 Washe r, Lo ck .438 Nut, He x .438 24 Exhaust Fle xib le Ho se Muffle r Exhaust Bracke t Nut, Whiz, Lo ck .312-18 Exhaust Muffle r Sid e 25 Muffle r Muffle r Exhaust Elb o w Raincap Air Cle ane r Elb o w Air Filte r Ind icato r Air Cle ane r Intake Tub e Air Cle ane r Ad ap te r Air Cle ane r Air Cle ane r Cap Air Cle ane r Oute r Filte r Ele me nt Air Cle ane r Inne r Filte r Ele me nt R.S. Eng ine Mo unt We ld me nt L.S. Eng ine Mo unt We ld me nt Scre w, HC 12mm X 1.75 X 30 Scre w, HC 12mm X 1.75 X 45 Washe r, Lo ck 12mm R.S. Re ar Eng ine Mo unt L.S. Re ar Eng ine Mo unt Scre w, HC 12mm X 1.75 X 30 Washe r, Lo ck 12mm Eng ine Iso lato rs Scre w, HC .500-13 X 5.50 Scre w, HC .500-13 X .75 Washe r, Flat .500 Nut, Lo ck .500-13
3
4 5 6
7 8 9 10 11 12 13 14 15 16
17
18
19
1 1 4 4 8 1 1 8 8 4 4 8 12 12
3.4.2
1
1 1 1 4 1 1 3 4 1 4 4
4800351 Due tz P/N 030-3808 030-3807 030-3809 223-9180 030-3795 336-3948 111-2322 111-1244 4800360 4210308 4800701 111-2322 4800702 U001485 U001420 U210160 4800769 U210100 U000900
Fro nt Guard Co ve r Asse mb ly He x Sp ace r Tub e Sp ace r Sup p o rt Bracke t Halte r Bracke t Be lt Guard Washe r HHCS Iso -4017 M8 X 20 A4C HHCS Iso -4014 M8 X 200 A4C Hyd raulic Pump Co up ling Pump Co up ling Ad ap te r Mo unting Plate HHCS ISO-M8 X 20 A4C Pilo t Plate Scre w, HC .750-10 X 3.50 G8 Scre w, HC .750-10 X 2.50 Washe r, Lo ck .750 Hyd raulic Pump Washe r, Lo ck .500 Scre w, HC .500-13 X 2.50
POWERTRAIN ASSEMBLY
TRANSMISSION DETAIL
12
17
18
14
13
16
15
11
19
7
10
9
8
6
5
4
2
3
1
McL 42 HD
3.4.3
POWERTRAIN ASSEMBLY McL 42 HD
ITEM # 1 2
3 4 5
6 7 8 9 10 11 12 13 14 15 16
17 18
19
QTY. 1 1 4 4 5 5 1 3 3 1 1 1 2 1 12 12 1 1 4 1 1 1 1 1 1 1 1 1 1 2 2 4 1 2 2 1 1 2 2 1 6
NUMBER 4800346 4810312 U001360 U210160 U001642 U210223 4810346 U000440 U200600 480034601 480034602 4800369 4810355 4000335 U001620 U210220 4810322 4800844 8030438 4800336 4810385 4810379 4810399 4810398 4810382 4800387 4810384 4801345 4800841 U000060 U000020 U210020 4800371 U210240 U210220 X000047 4801309 U000040 U200020 4810389 U030050
TRANSMISSION DETAIL
DESCRIPTION Transmission Transmission Support Weldment Screw, HC .750-10 X 1.50 Washer, Lock .750 Screw, HC 12mm X 1.75 X 30mm Washer, Lock 12mm Coupling Guard Screw, HC .375-16 X 1.25 Washer, Flat .375 Transmission Shaft Rod Transmission Shaft Knob Bell Housing Bell Housing Side Cover (Not Shown) Cover Plate, Bottom (Not Shown) Screw, HC 10mm X 1.50 X 25mm Washer, Lock 10mm Eng/Trans Support Spacer Enclosure, Clutch Relay Screw, PH 10-24 X .750 Bracket, Enclosure, Clutch Solenoid Clutch Sleeve Ant-Rotation Bracket Hydraulic Clutch - Model 211 Clutch Drive Shell Bell Housing Spacer Bearing Bearing Carrier Engine Vent Junction Box Screw, HC .250-20 X 1.00 Screw, HC .250-20 X .500 Washer, Lock .250 Mount Plate Screw, HC M10 X 30mm Washer, Lock 10mm V-Belt Solenoid Bracket, V-Belt Solenoid Screw, HC .250-20 X .750 Washer, Flat .25 Clutch Capture Spacer Screw, SFH .3125-18 x .750
3.4.4
POWERTRAIN ASSEMBLY McL 42 HD
3.4.5
GEARBOX DETAIL
POWERTRAIN ASSEMBLY McL 42 HD
ITEM # 1
11
QTY. 1 4 1 40 40 1 4 2 1 4 4 1 1 1 1 2 2 2 1 1 4 4 1
NUMBER 4800302 4800307 4800103 U001440 U210160 4800306 U030010 W200195 4800348 U001380 U210160 U420041 4810330 4810331 4810332 U010250 U010261 U100140 4810333 4800395 U210110 U070030 4810339
12
2 2 2
U200100 U120015 3600131
13 14
1 1
15 16
1 1
4801306 4801303 U024010 U022155 3600115
2
3 4 5
6 7 8
9 10
GEARBOX DETAIL
DESCRIPTION Ge arb o x Ge arb o x Se al Plate Ad ap te r Scre ws Ge arb o x Ad ap te r Ring Scre w, HC .750-10 x 2.00 (No t Sho wn) Washe r, Lo ck .750 (No t Sho wn) Ge arb o x Se al Plate Scre w, SFH .250-20 X .563 O-Ring Shaft, Inp ut Ad ap te r Scre w, HC .750-10 X 2.00 Washe r, Lo ck .750 Ke y Co up ling Flang e Ce nte r Me mb e r Co up ling Ad ap te r Scre w, HSH .500-13 X 3.75 Scre w, HSH .500-13 X 4.75 Nut, He x .500-13 Co mp anio n Flang e Drag Brake Disk Washe r, H-C .500 Scre w, CB, 12Pt. .500-13 X 3.25 Drag Brake Mo unt Asse mb ly Co ntains: 4810338 Brake Mo unt 4810336 Brake Mo unt Blo ck U000180 Scre w, HC 5/16-18 X 3/4 U210040 Washe r, Lo ck 5/16 Washe r, Flat .500 Nut, Nylo c.500-20 Bulkhe ad Ad ap te r Kit Co ntains: 1 Fie ld Hub 2 Nut, Jam Brake Band Brake Band Cab le Lo ck Scre w, Se t .250-20 X .500 KN Cup Scre w, Sho uld e r .375 x 1.00 Thro ttle Cab le
3.4.6
DOG PLATE ASSEMBLY McL 42 HD
3.5.1
DOG PLATE ASSEMBLY McL 42 HD
ITEM #
QTY.
1 2 3 4
1 2 2 2 2 2 4 2 2 2 4 4 4 3 1 2 1 1 8 8 4 4 1 1 1 2 2 2 2
5 6
7 8 9
10
NUMBER
DESCRIPTION
4210402 4210410 U600060 W000070 4800418 U001505 U200160 U100200 4800808 4800437 U000060 U100020 U200020 4800430 4801710 U001505 4810401 4800425 U000400 U210060 U000400 U200060 4800412 4800413 4800414 U000060 U210020 U200020 U120100
Dog Plate D og P i n Dog Pin Compression Spring Dog Plate Roller Roller Spacer Screw, HC .750-10 X 4.00 G8 Washer, Flat, Large .750 Nut, HC .750-10 Dog Plate Switch Switch Mount Screw, HC .250-20X1.00 Nut, Hex .250-20 Washer, Flat .250 Cylinder Pin Dog Pin Cylinder Screw, HC .750-10 X 4.00 Cylinder Cover Box Top Cover Screw, HC .375-16 X .750 Washer, Lock .375 Screw, HC .375-16 X .750 Washer, Flat .375 Outlet Box Outlet Cover Outlet Grommet Screw, HC .250-20 X 1.00 Washer, Lock .250 Washer, Flat .250 Nut, Lock .250-20
3.5.2
42” CASING PUSHER/SPOIL EJECTOR McL 42 HD
3.6.1
42” CASING PUSHER/SPOIL EJECTOR McL 42 HD
ITEM #
QTY.
NUMBER
DESCRIPTION
1
1 4 4 4 1 1 1 1 12 12 1 1
4210501 4810129 4810134 U001570 4800514 4800550 U320015 4800515 U001584 U210210 4210523 4210528
42" Casing Pusher Anchor Pins Heavy Duty Washer Screw, HC 1-8 X 5.00 G5 Spoil Door Hinge Rod Pin, Cotter 1/8 X 1.00" 4" Hex Chuck Screw, HC 1 1/8 - 12 X 3.50" Washer, Lock 1 1/8" 42" Paddle Assembly 42" Saddle
2
3
4 5
Optional Equipment (Available upon request)
6
7
A A740201108102 A 700200 A 421012 A 700240 A 421018 A 700300 A 421020 A 700360 A 421024 A 470020 A042201102300 U A 6 A7402012003S A 70024S A7402003000S 34 A A A7402003060S 35 A A7609004122S S U A020000808306 U A26190011080S U A16090012240S
A Addaapptteerr K Kiitt,, 1182"" Adapter Kit, 20" Adapter Kit, 16" Adapter Kit, 24" Adapter Kit, 18" Adapter Kit, 30" Adapter Kit, 20" Adapter Kit, 36" Adapter Kit, 24" Adapter Kit, 42" Acdraepwt,eS rK S Qit.,73500"-10 x 3.50 (3 Req'd) A d a p t e r K Shoe, 20" iAt,d3a6p"ter Shoe, 24" Adapter Shoe, 3102" Adapter S S Shhooee,, 316" Adapter S Shhooee,, 4128" Adapter S Schroeew,,2H0C " A.5d0a0p-t1e3r X 2.00 (4 Req'd) W a s h e r , L Shoe, 24"oAcdka.5p0te0r (4 Req'd) N 00d-a1p3te(r4 Req'd) Suhto, eH,e3x0."5A
A 69030S
Shoe, 36" Adapter
3.6.2
MASTER TRACK ASSEMBLY McL 42HD
3.7.1
MASTER TRACK ASSEMBLY McL 42HD
ITEM # 1 2 3 4 5 6
QTY. 3 1 1 40 40 40
NUMBER 4210601 4210609 4210614 U001420 U210160 U100200
DESCRIPTION Master Track Extension Track Push Plate Screw, HC .75-10 X 2.50 Washer, Lock .750 Nut, Hex .750-10
3.7.2
HYDRAULIC TANK ASSEMBLY McL 42HD
HYDRAULIC TANK ASSEMBLY McL 48/54
ITEM # 1 2 3 4 5 6 7
QTY. 1 2 1 1 1 1 2
NUMBER 4210702 4800758 4800759 T720060 4800761 4210711 T405060
DESCRIPTION Hydraulic Tank Clean Out Cover Kit Fill Assembly Kit Sight Gauge Kit Suction Strainer Return Filter Drain Plug
3.8.1
FUEL TANK ASSEMBLY McL 42HD
FUEL TANK ASSEMBLY McL 48/54
ITEM # 1 2 3
QTY. 1 1 1
NUMBER 4210220 4800278 8010006
DESCRIPTION Fuel Tank Lockable Fuel Cap Kit Sight Gauge, 6" Kit
3.9.1
HYDRAULIC SYSTEM
HOSES AND FITTINGS
McL 42 HD
4.1.1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
4.1.2 HOSE ROUTING BASE MANIFOLD -- BASE CYLINDER QUICK DISC MALE LEFT CYLINDER, BASE END -- BASE MANIFOLD P2 RIGHT CYLINDER, BASE END -- BASE MANIFOLD P3 ROD MANIFOLD -- ROD CYLINDER QUICK DISC FEMALE LEFT CYLINDER, ROD END -- ROD MANIFOLD P2 RIGHT CYLINDER, ROD END -- ROD MANIFOLD P3 TRACK BRAKE -- QUICK DISC DOG PLATE CYLINDER -- HOUSING COUPLING
1 2 3 4
#
T400545 T401635 T405120 T401710 T401586 T400392 T400546 T401700 T400028 T401065 T400803 T412008 T412010 T403060 T400024 T400815 4800776 4800775
PART NO.
TH42001 TH42002 TH42003 TH42004 TH42005 TH42006 TH42007 TH42008
PART NO.
CYLINDER MANIFOLD (QTY 2) THRUST CYLINDER (QTY 2) TRACK BRAKE CYLINDER DOG PLATE CYLINDER
HYDRAULIC COMPONENTS 4800731 4800729 4810750 4801710
PART NO.
McL 42 HD
1 2 3 4 5 6 7 8
UNION 16MB-16MF ELBOW 90 16MB-16MF PLUG 16MB ELBOW 90 20MB-16MF UNION 45 16FP-16FP BULKHEAD 45 16MJ-16MJ UNION 16MP-16MF SWIVEL 90 4MP-6MJ UNION 6MJ-6MP ELBOW, 90 6FP-6MP UNION 6MP-6MP QUICK DISC, MALE 6FP CAP QUICK DISC UNION 16MP-8FP UNION 8MP-6FP UNION 16FJ-16MP QUICK DISC FEMALE 16FP QUICK DISC MALE 16FP
FITTING DESCRIPTION
HYDRAULIC SYSTEM HOSES AND FITTINGS
See page 4.1.4 for fittings and components callout
HYDRAULIC SYSTEM McL 42 HD
CARRIAGE
4.1.3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49
FITTING DESCRIPTION
ELBOW, 45 32MP-32MJ KIT #32 SPLIT FLANGE COMPLETE ELBOW, 90 10MB-12MJ ELBOW, 90 12MP-12MJ UNION, 12MP-6MJ UNION, 12MP-12MP UNION, 12MP-6MJ ELBOW, 90 6FJ-6MJ UNION, 24MB-24MJ ELBOW, 90 24FJ-24MJ TEE, 6FJ-6MJ-6MJ ELBOW, 90 6MB-6MJ UNION, 6MB-6MB QUICK DISC., FEMALE 6FP DUST CAP, QUICK DISC., 6FP UNION, 6MP-6MJ UNION, 6MB-6MJ UNION, 4MB-4MJ ADAPTER, SPLIT FLANGE 16FB UNION, 8MB-8MJ UNION, 16MB-16MF ELBOW, 90 6MB-8MJ ELBOW, 90 6MB-6MJ UNION, 6MB-6MB UNION, 8MB-10MJ UNION, 10FJ-6MJ UNION, 8MB-4MJ ELBOW, 90 10MB-8MJ UNION, 16MB-16MF UNION, 4MB-4MJ TEE, 4FJ-4MJ-4MJ UNION, 4FP-4MJ UNION, 16MB-16MF UNION, 16MF-16MP QUICK DISC., MALE 16FP QUICK DISC., FEMALE 16FP PLUG, 8MP O-RING #6 SAE ELBOW, 90 6FJ-6MJ UNION, 6FJ-6FP UNION, 6MP-6MP QUICK DISC., MALE 6FP UNION, 12MP-8FP
NOTE: For replacement Hose Assemblies,
please include hose length and end fittings. 4.1.4 T401228 T400083 T400803 T412008 T403085
T405062 W200015
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
15
14
12 13
8 9 10 11
7
1 2 3 4 5 6
PART NO. TH48120 TH48121 TH48122 TH48123 TH48124 TH48125 TH48126 TH48127 TH48128 TH48129 TH48130 TH48131 TH48132 TH48133 TH48134
HOSE ROUTING HYD. TANK — PUMP (INLET) CASE DRAIN — HYD. TANK MANIFOLD DRAIN — HYD. TANK 2ND FILTER PRV #3 — MANIFOLD TEE DRAIN PLUMBING MANIFOLD — CHECK VALVE MANIFOLD MANIFOLD, V1 — DOG PLATE CYLINDER MANIFOLD, V2 — TRACK BRAKE CYLINDER PUMP (OUTLET) — PRV #2 PUMP #X — SHUTTLE VALVE #2 CONTROL VALVE #T — HYD. TANK MAIN FILTER SHUTTLE VALVE #3 — CONTROL VALVE L.S. TEE PUMP (OUTLET) — CONTROL VALVE #P1 CONTROL VALVE L.S. TEE — PRESSURE GAUGE CONTROL VALVE #B — FITTING BULKHEAD ROD END CONTROL VALVE #A — FITTING BULKHEAD BASE END
T404010 T400027 T400710 T402148 T400391 T400035 T400039 T400033 T400290 T400705 T400036 T401290 T400160 T400142 PART NO. 4800723 T700080 4800769 4800778 4800784 4800765 4801720 4801700 4801703 2400367 4800785 4210715 4801701 4801702 4810712 3600345 3600346 3600347 2400368 2400367 T720012
UNION, 8MP-6FP UNION, 6MP-6MB UNION, 8FJ-6MB TEE, 6MB-6MJ-6MJ BULKHEAD, 6MJ-6MJ UNION, 10MB-6MJ UNION, 6FJ-4MJ UNION, 6MJ-5MB UNION, 24MJ-16MB UNION, 8FJ-6MJ UNION, 6MB-6FJ ELBOW,90 10MB-6MJ UNION, 10MB-8MJ UNION, 8FJ-6MP
PART NO.
HYDRAULIC COMPONENTS IN-TANK RETURN FILTER SECOND CIRCUIT RETURN FILTER HYDRAULIC PUMP CONTROL VALVE PRESSURE GAUGE PRESSURE REDUCING VALVE BODY CARTIDGE SHUTTLE VALVE BODY CARTIDGE PLUMBING MANIFOLD CHECK VALVE MANIFOLD, SECOND CIRCUIT SOLENOID VALVE (V1 & V2) CARTIDGE COIL CLUTCH PRESSURE REDUCING VALVE ASSEMBLY CLUTCH SOLENOID VALVE CARTIDGE BODY COIL FILTER SCREEN ASSEMBLY FILTER SCREEN CARTIDGE FILTER SCREEN BODY CLUTCH PRESSURE GAUGE (0-600 PSI)
50 51 52 53 54 55 56 57 58 59 60 61 62 63
FITTING DESCRIPTION
McL 42 HD
T400545 T400546 4800775 4800776
T400570 T402010 T400110
T400038 T412009 T412010 T400028 T400037 T400570 4800767 T400140 T400545 T401260 T401250 T400038 T400400 T403130 T400134 T401300 T400545
T401565 T410450 T401581 T401180 T400085 T400800 T400085 T401228 T400580 T401730 T402153 T401250
PART NO.
HYDRAULIC SYSTEM CARRIAGE
ELECTRICAL SYSTEM
WIRING DIAGRAM ENGINE DETAIL
McL 42 HD
4.2.1
ELECTRICAL SYSTEM
WIRING DIAGRAM JUNCTION BOX DETAIL
McL 42 HD
4.2.2
WIRING DIAGRAM
CONTROL BOX
HYDRAULIC CLUTCH SOLENOID (NO POLARITY)
McL 42 HD
4.2.3
WIRING DIAGRAM
INSTRUMENT PANEL
McL 42 HD
4.2.4
COMPONENT WIRING
WIRING DIAGRAM McL 42 HD
4.2.5
5.2 -5.8 MACHINE COMPONENTS McL 42 HD
DETAIL
PAGE
GEARBOX TRANSMISSION PARTS HYDRAULIC PUMP COUPLING HYDRAULIC CLUTCH HYDRAULIC THRUST CYLINDER HYDRAULIC DOG PLATE CYLINDER HYDRAULIC VALVE
5.2.1-5.2.3 5.3.1-5.3.14 5.4.1 5.5.1 5.6.1 5.7.1 5.8.1
5.2.0
GEARBOX COMPONENTS McL 42 HD
5.2.1
GEARBOX COMPONENTS McL 42 HD
IT E M # 1A 1K 1I 1G 1C 1D 1E 1F 1B 1L 1N 5 24 1M 17 18 1U 3C 3B 3E 3A 3F 1J 1H 4 3G 3D 3H 16 15 26 13 25 1V 1T 7 1P 22 6 8 6
QT Y. 1 1 4 1 1 1 1 1 1 1 8 2 1 8 16 4 1 6 3 3 1 1 1 1 1 3 6 3 2 4 1 1 2 2 1 2 3 20 1 1 1
N U MB E R 480030201 480030202 480030203 480030204 480030205 480030206 480030207 480030208 480030209 480030210 480030211 480030212 480030213 480030214 480030215 480030216 480030217 480030218 480030219 480030220 480030221 480030222 480030223 480030224 480030225 480030226 480030227 480030228 480030229 480030230 480030231 480030232 480030233 480030234 480030235 480030236 480030237 480030238 480030239 480030240 480030241
MODEL# SERIAL #
D E S C R IP T ION Spindle Carrier, Bearing Plate, Rectangular Housing Bearing, Tapered Bearing, Tapered Bearing, Tapered Bearing, Tapered Seal, Face Shim, Steel Bolt, Hex-Special O-Ring Plate, ID Bolt, Hex-UNC Bolt, Hex-UNC Bolt, Shoulder Seal, Boot Bearing, Cup Pin, Roll Shaft, Planet Carrier Gear, Cluster Set Gear, Internal Coupling, Internal Gear, Ring Spacer, Thrust Bearing, Tapered Ret, Ring-Extension Bearing, Thrust Washer, Thrust Spacer, Input Gear, Sun Screw, Drive Pipe Plug, STD-NPT Pipe Plug, STD-NPT Pipe Plug, MAGN-NP Pipe Plug, MAGN-NP Washer, Lock Plug, Cardboard Washer, Thrust Cover, Input
Note: McLaughlin Manufacturing Co. is not authorized to service Gearboxes. Consult McLaughlin Manufacturing Co. for repair manual or the name of an authorized service dealer near you.
5.2.2
GEARBOX MAINTENANCE SCHEDULE McL 42 HD
DATE/HRS
SERVICE PERFORMED
5.2.3
BY
TRANSMISSION COMPONENTS McL 42 HD
MODEL# SERIAL #
Note: McLaughlin Manufacturing Co. is not authorized to service transmissions. Consult an authorized dealer of the transmission manufacturer for parts and /or service. Transmission model and serial number is required for part orders. Contact McLaughlin Manufacturing Co. for a distributer near you.
5.3.1
TRANSMISSION DETAIL McL 42 HD
SHIFT BAR HOUSING
5.3.2
TRANSMISSION DETAIL McL 42 HD
5.3.3
TRANSMISSION DETAIL McL 42 HD
LEVER ASSEMBLY
5.3.4
TRANSMISSION DETAIL McL 42 HD
5.3.5
TRANSMISSION DETAIL McL 42 HD
TRANSMISSION CASE
5.3.6
TRANSMISSION DETAIL McL 42 HD
5.3.7
TRANSMISSION DETAIL McL 42 HD
TRANSMISSION CASE
5.3.8
TRANSMISSION DETAIL McL 42 HD
5.3.9
TRANSMISSION DETAIL McL 42 HD
TRANSMISSION CASE
5.3.10
TRANSMISSION DETAIL McL 42 HD
5.3.11
TRANSMISSION DETAIL McL 42 HD
INPUT SHAFT
5.3.12
TRANSMISSION DETAIL McL 42 HD
5.3.13
TRANSMISSION MAINTENANCE SCHEDULE McL 42 HD
DATE/HRS
SERVICE PERFORMED
5.3.14
BY
HYDRAULIC PUMP COUPLING McL 42 HD
HYDRAULIC PUMP COUPLING McL 42 HD
ITEM # 1
2 3 4
QTY. 1 1 1 1 1 4 1 8
NUMBER 4800355 4800356 U010220 4800357 4800358 U010085 4210308 U030900
DESCRIPTION Coupling Hub Snap Ring Screw, HSH .438-14X1.50" Nylon Sleeve Pully Hub Screw, HSH .375-16X1.25" Pully Flange Screw, Soc 8mm X 30mm
5.4.1
HYDRAULIC CLUTCH ASSEMBLY McL 42 HD
HYDRAULIC CLUTCH ASSEMBLY ITEM# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
QTY 1 1 1 1 1 1 1 1 6 6 2 6 1 3 1 1 3 1 2 1 1
NUMBER 481039901 481039902 481039903 481039904 481039905 481039906 481039907 481039908 481039909 481039910 481039911 481039912 481039913 481039914 481039915 481039916 481039917 481039918 481039919 481039920 481039921
5.5.1
DESCRIPTION RETAINING RING ANGULAR CONTACT BEARING (7215) ANGULAR CONTACT BEARING (7217) CYLINDER ASSEMBLY PISTON SPACER BEARING HUB SEPARATOR PLATE HIGH COLLAR LOCK WASHER 5/16-18 UNC X 0.75 LG SHCS FRICTION DISC COMPRESSION SPRING SPACER 1/4-20 UNC X 0.50 LG FHSCS O-RING O-RING 5/16-18 UNC X 0.625 LG FHSCS PRESSURE PLATE #10-24 X 0.75 LG SHCS HUB BACKPLATE
HYDRAULIC THRUST CYLINDER McL 42 HD
HYDRAULIC CYLINDER McL 42 HD
ITEM # 1 2 3 4 5 6
QTY. 1 1 1 1 1 1
NUMBER 480072901 480072902 480072903 480072904 480072905 480072906
DESCRIPTION Tube Assembly Rod Assembly Piston Rod Gland Assembly Lock Nut S eal K i t
Complete Seal Kit to include: IT E M # A B C D E
QT Y. 1 1 1 1 1
D E S C R IP T ION Piston Seal Rod Seal Wiper O-Ring O-Ring & Back Up
5.6.1
COMPONENTS
HYDRAULIC THRUST CYLINDER McL 42 HD
5.6.2
SEAL DETAILS
HYDRAULIC DOG PLATE CYLINDER McL 42 HD
ITEM# 1 2 3 4
QTY 1 1 1 1
NUMBER 4801710-05 4801710-15 4801710-10 4801710-20
DESCRIPTION Threaded Cap Rod/Clevis Weldment Barrel/Clevis Weldment Seal Kit
HYDRAULIC DOG PLATE CYLINDER
SEAL KIT ASSEMBLY
McL 48/54
New Seal Kit Reference Print
O-RING #218
O-RING #014
O-RING #131
5.7.1
O-RING #210
WIPER
HYDRAULIC VALVE PARTS McL 42 HD
VALVE HANDLE - MAIN THRUST VALVE McL 48/54
ITEM # 1 2 3
QTY. 1 1 1
NUMBER 4800810 3610713 4800854
DESCRIPTION Grip with Switch Valve Lever Adapter Switch Adapter
5.8.1
HYDRAULIC CLUTCH McL 42 HD
6.1 OPERATING NOTE: 1. Engaging the clutch against an immovable load, will cause premature failure of the clutch. Do not cycle the clutch (on/off/on/off etc.) with augers under-load. COLD WEATHER OPERATION Cold weather affects the operation of the boring machine. Cold hydraulic fluid causes sluggish machine performance and can contribute to the premature failure of some machine components. Before starting to bore, the machine and hydraulic fluid must be at operating temperature (i.e. the machine must be warmedup before boring). Warm-up procedure: 1. Start the machine and let it run at idle for 1-2 minutes. 2. Slowly increase the engine rpm to about 1/2 to 3/4 full throttle 3. Allow the engine to run at this higher speed for 4-5 minutes 4. Extend and retract the thrust cylinders to warm up the hydraulic fluid. 5. Occasionally running the machine over relief will help to reduce the warm-up time. Only after the machine is warmed up should you begin to bore! Hydraulic Clutch Operation: SLUGGISH OR DELAYED APPLY TIME FOR THE CLUTCH CAN CAUSE PREMATURE FAILURE. The apply time for the clutch (the time it takes to build full pressure) is critical to the operation of the machine. Normal clutch apply time is less than 2 seconds. If the apply time is greater than 2 seconds, wait until the oil temperature increases before boring. The apply time can be monitored by the pressure gauge on the console panel. Cycle the clutch during warm-up, waiting 10 seconds between engagements. WHEN APPLYING THE CLUTCH DURING THE WARM-UP PERIOD, THE TRANSMISSION MUST BE IN NEUTRAL. Do not cycle the clutch during warm-up while coupled to loaded augers. Boring with an extended clutch apply time will cause premature failure of the clutch. The hydraulic clutch operating system has 2 switches. 1. O.P.C. Switch 2. Clutch Switch Both the O.P.C. switch and the Clutch switch must be in the “ON” position before the clutch will operate. If the clutch does not operate, make sure that both of these switchs are “ON”. The hydraulic pressure is set at the factory for 225 psi. This pressure must be maintained for proper operation. DO NOT operate the clutch if the clutch pressure gauge is reading below 150 psi. Too low an operating pressure will result in premature clutch failure.
6.1.1
HYDRAULIC CLUTCH McL 42 HD
COLD WEATHER OPERATION Hydraulic Fluid: Use the alternate hydraulic fluid for the following: - To reduce warm-up time before boring. - When consistently boring in cold weather. Standard hydraulic fluid: - ISO grade #46 with anti-wear additives. - 76 Unax AW #46 - Or equivalent Alternate hydraulic fluid: - ISO grade #32 Wide Temperature Range oil with anti-wear additives. - 76 Unax AW-WR #32 - Or equivalent Consult McLaughlin for more information.
6.1.2
HYDRAULIC CLUTCH McL 42 HD
6.2 TROUBLESHOOTING DANGER: DO NOT OPERATE MACHINE IF CLUTCH IS NOT OPERATING PROPERLY. DEATH OR SERIOUS INJURY WILL RESULT. The hydraulic clutch supplied with this machine is a dry-running, self-adjusting, twin-disk clutch. The clutch requires very little maintenance. Following is a list of symptoms which may require servicing the clutch. 1. Contamination The clutch is designed to run in a dry environment. However, the clutch housing can become contaminated. Contamination can result from dirt or sandy grit, oils, or water (which causes rust) entering the clutch housing. Clean the disc pack kit with kerosene to restore to normal condition. 2. Drag in Neutral It is natural for a twin-disc clutch to have a small amount of drag in the disengaged state. The drag should be more noticeable at low engine speeds and in low transmission gears. A. New machines or rebuilt clutches There is an indeterminate break-in time required for new clutches. Once a clutch has been working for a while, it should seat itself and neutral drag should be at a minimum. B. Abrupt changes in clutch drag If the drag in the clutch abruptly increases, it may be due to insufficient spring tension between the clutch discs. Weaker springs cause more drag between the discs of the clutch. Excessive heat, generated in the clutch by cycling the clutch or by applying the clutch against locked augers, will weaken the springs and cause excessive nuetral drag. Replace disc pack kit and inspect all other components for damage and replace as necessary. Refer to the Clutch Components and Disassembly/Assembly section of this manual for components and proper clutch service procedures.
6.2.1
5.1 ENGINE DETAILS McL 42 HD
DETAIL
PAGE
ENGINE DESCRIPTION MODEL DESIGNATION ENGINE PARTS LUBE OIL CIRCUIT FUEL SYSTEM SCHEMATIC ENGINE COOLING COMMISSIONING STARTING MONITORING SYSTEMS STOPPNG OPERATING CONDITIONS LUBE OIL OPERATING MEDIA MAINTENANCE SCHEDULE LUBRICATION SYSTEM FUEL SYSTEM COOLING SYSTEM CUMBUSTION AIR FILTER BELT DRIVES ADJUSTMENTS ACCESSORIES/BATTERY ENGINE CLEANING ADDITIONAL MAINTENANCE DIAGNOSIS CHART ENGINE PRESERVATION ENGINE SPECIFICATIONS AND SETTINGS TORQUE WRENCH SETTINGS/TOOLS ORDERING SPARE PARTS
5.1.1 5.1.2-5.1.3 5.1.4-5.1.5 5.1.6 5.1.7 5.1.8 5.1.9-5.1.10 5.1.11 5.1.12 5.1.13 5.1.14 5.1.15 5.1.16 5.1.17-5.1.18 5.1.19-5.1.20 5.1.21 5.1.22 5.1.23-5.1.24 5.1.25-5.1.26 5.1.27 5.1.28-5.1.29 5.1.30 5.1.31 5.1.32 5.1.33 5.1.34-5.1.35 5.1.36 5.1.37
5.1.0
ENGINE DESCRIPTION GENERAL 1
DEUTZ Diesel Engines
Service and Maintenance
DEUTZ Service
are the product of research and development ranging over many years. The know-how thereby gained, coupled with high demands with regard to quality, forms the guarantee for the manufacture of engines featuring long service-life, high reliability, and low fuel consumption. It goes without saying that the high demands regarding protection of the environment are also fulfilled.
will also play a decisive role as to whether the engine fulfills to your satisfaction the demands you make on it. Observance of the prescribed maintenance intervals and careful carrying out of the service and maintenance jobs are therefore essential. Particular attention must be given with regard to applications involving differing and harder operating conditions as compared with normal operation.
In case of operational troubles and queries concerning spare parts, please contact your DEUTZ agent. Where necessary, our trained specialists will ensure a quick and professional repair, using DEUTZ spare parts. Genuine DEUTZ spare parts are always manufactured to the latest technical standards. More information on DEUTZ SERVICE can be found at the end of this Operation Manual.
Beware of Running Engine
Safety
Shut the engine down before carrying out maintenance or repair work. Ensure that the engine cannot be accidentally started - accidents may otherwise occur. When the work is complete, be sure to refit any panels and guards that have been removed. Never fill the fuel tanks while the engine is running. Observe industrial safety regulations when running the engine in an enclosed space or underground.
When reading through this Manual, you will find this symbol marking all safety instructions and proceed with special care. Pass on these safety instructions to your operating personnel. In addition, it is also necessary to observe the official safety and accident prevention rules.
5.1.1
The seals and gaskets used in this engine are asbestos-free. When carrying out maintenance and repair work, please use appropriate spare parts.
MODEL DESIGNATION 2.1 Model
2.1.1 Rating Plate The model designation A, the engine serial number B and the performance data are stamped on the rating plate. The model and engine serial number must be given when ordering parts.
2.1.2 Location of Rating Plate The rating plate C is attached to the crankcase; depending on the design, a second rating plate may be attached to the air duct.
2.1.3 Engine Serial Number The engine serial number D is stamped onto the crankcase as well as on the rating plate.
2.1.4 Numbering of Cylinders The cylinders are numbered consecutively, beginning at the flywheel end.
Adjustments to the regulator are to be carried out only by authorized DEUTZ SERVICE - specialists.
5.1.2
ENGINE DESCRIPTION 2.1 Model
2.1.5 Direct Injection FL 912 Engines with direct injection are used where high performance is required.
2.1.6 Two-stage Combustion FL 912W Engines with two-stage combustion are used where it is particularly important to keep exhaust emissions to an absolute minimum.
5.1.3
ENGINE DESCRIPTION
2.2 Engine Illustrations
2.2.1 Service Side F4L 912 1 Fan 2 V-belt (fan) 3 Injection pump 4 V-belt (alternator) 5 V-belt pully 6 Tension roller 7 Oil fill point 8 Oil pan 9 Oil drain plug 10 Fuel pump 11 Oil dipstick 12 Lube oil filter 13 Easy-change fuel filter 14 Air duct cover 15 Cylinder-head cover
2.2.2 Exhaust Side F4L 912 16 17 18 19 20 21 22 23
5.1.4
Air intake pipe Exhaust manifold pipe Screen Alternator Starter Engine mounting Crankcase Crankcase ventilation
ENGINE DESCRIPTION
2.2 Engine Illustrations
2.2.3 Service Side BF4L 913 1 Fan 2 V-belt (fan) 3 V-belt (alternator) 4 V-belt pully on crankshaft 5 Tension roller 6 Oil fill point 7 Oil drain plug 8 Fuel filter cartridge 9 Fuel pump with fuel precleaner 10 Injection pump 11 Oil dipstick 12 Lube oil filter cartridge 13 Air duct cover 14 Engine oil radiator cover
2.2.4 Exhaust Side BF4L 913 15 16 17 18 19 20 21 22
Exhaust manifold line Terminal housing Starter Crankcase ventilation Oil pan Alternator Exhaust turbocharger Air-intake pipe-exhaust turbocharger 23 Charge-air line
5.1.5
ENGINE DESCRIPTION 2.3 Lube Oil Circuit
2.3.1 Lube Oil Circuit FL 912/913 1 Oil Pan 2 Intake Manifold 3 Oil pump 4 Oil pressure control valve 5 Pressure-oil line 6 Bypass line or selectively 7 Finned pipe spiral or selectively 8 Frame oil cooler 9 Lube oil filter 10 Safety valve 11 Main oil gallery 12 Crankshaft bearing 13 Con-rod bearing 14 Camshaft bearing 15 Tappets 16 Push rod (hollow, for oil feed to rocker arm lubrication) 17 Rocker arm bearing 18 Metering plug (r arm lubrication)* 19 Protective sleeve for push rod 20 Throttle bore (for lubrication of the gear wheels) 21 Injection jet for cooling the pistons 22 Connection for oil pressure gauge 23 Oil pressure gauge 24 Injection pump connected to lube oil circuit 25 Connection point for oil heating**
1 Oil Pan 2 Intake manifold 3 Oil pump 4 Oil pressure control valve 5 Pressure-oil line 6 Connecting line to oil cooler 7 Frame oil cooler 8 Lube oil filter 9 Safety valve 10 Main oil gallery 11 Crankshaft bearing 12 Con-rod bearing 13 Camshaft bearing 14 Tappets (with impulse lubrication of the rocker arm) 15 Push rod (hollow, for oil feed to r. arm lubrication) 16 Rocker arm bearing 17 Metering plug (r arm lubrication)* 18 Protective sleeve for push rod (oil return form cylinder head to crankcase) 19 Throttle bore (for lubrication of the gear wheels) 20 Injection jet for cooling the pistons 21 Oil line for lub. of the exhaust turbocharger 22 Oil ret. line from exhaust turboc. to the crankcase 23 Oil pressure gauge 24 Partial flow lube oil filter 25 Connection point for oil heating** 26 Injection pump connected to lube oil circuit
2.3.2 Lube Oil Circuit BF6L 913
5.1.6
* only for inclined engines ** in this instance the filter holder must be replaced. Please contact our service representative for this alteration.
ENGINE DESCRIPTION
2.4 Fuel System Schematic
2.4.1 Fuel Circuit 1 2 3 4 5 6 7 8 9 10 11
5.1.7
Fuel Tank Fuel line from tank to fuel pump Fuel supply pump Easy-change fuel filter Injection pump Injection lines Injection valves Oil leakage line Fuel overflow valve Overflow valve Fuel return line to tank A Clearance: keep as far apart as possible.
ENGINE OPERATION 2.5 Engine Cooling
2.5.1 Regulation of Coolant Flow using the Exhaust Thermostat 1 Pressure-oil line from engine to exhaust thermostat 2 Air line to exhaust thermostat 3 Exhaust manifold pipe 4 Exhaust thermostat 5 Control line to hydraulic coupling 6 Hydraulic coupling 7 Cooling fan 8 Cooling fan drive 9 Oil return line to crankcase 10 Ventilation line 11 Adjusting pin with special seal
2.5.2 Regulation of Coolant Flow using the Exhaust Thermostat and Solenoid 1 Pressure-oil line from engine to exhaust therostat 2 Air line to exhaust thermostat 3 Exhaust manifold pipe 4 Exhaust thermostat 5 Control line to hydraulic coupling 6 Hydraulic coupling 7 Cooling fan 8 Cooling fan drive 9 Oil return line to crankcase 10 Ventilation line 11 Adjusting pin with special gasket 12 Solenoid
5.1.8
ENGINE OPERATION
3.1 Commissioning
3.1.1 Adding Engine Oil
3.1.2 Filling Oil Bath Air Cleaner
3.1.3 Adding Fuel
As a rule, engines are delivered empty of oil. Pour lube oil into the oil filler neck (arrow). For oil grade and viscosity, see pg 4.1
Fill oil cup 1 of the oil bath air cleaner with engine oil up to the arrow. For oil grade and viscosity, see 4.1
Use only commercial-grade diesel fuel. For fuel grade see 4.2. Use summer or winter-grade fuel, depending on the ambient temperature.
Oil may not be filled into the dust collector of the precleaner, if this is fitted.
3.1.4 Ventilation Model: “Bosch” fuel pump
Never fill the tank while the engine is running. Keep the filler cap area clean and do not spill fuel.
3.1.4 Ventilation Model: “IMSA” fuel pump
Loosen overflow valve 1 at the lower (larger) hexagon. Loosen hand pump 2 at the notched grip 3 by unscrewing by several turns to the left. Actuate hand pump 2 until bubble-free fuel is emitted at the loosened overflow valve 1. Tighten overflow valve1, continuing to pump at the same time. Tighten grip 3.
Loosen overflow valve 1 at the lower (larger) hexagon. Actuate preliminary pump lever 2 against the spring pressure until bubble-free fuel is emitted at the loosened overflow valve 1. Tighten overflow valve 1, continuing to pump at the same time.
5.1.9
ENGINE OPERATION
3.1 Commissioning
3.1.5 Other Preparations Check battery and cable connections see 6.7.1 Transport hooks Remove if fitted (see 6.7.3)
3.1.6 Additional Maintenance Work The following maintenance should be carried out after 50-150 operating hours: Change lube oil, see 6.1.2
Trial run After the engine has been prepared, let it run for about 10 minutes without load.
Change oil filter cartridge, see 6.1.3 Change fuel filter cartridge, see 6.2.1
During and after trial run - Check the engine for leaks.
Check V-belts and retension as necessary, see 6.5
After the engine has been turned off - Check the oil level, see 6.1.2 If necessary, top oil, see 3.1.1 Retension V-belts, see 6.5
Check valve clearance and adjust as necessary, see 6.6.1 Check the engine for leaks.
Breaking in During the break-in phase - about 200 operating hours - check the oil level twice a day. After the engine is broken in, checking once a day will be sufficient.
Check the engine mount and adjust as necessary, see 9.2
3.1.7 Selector Switch for Oil Heater
Position of selector switch for oil filter console with oil heater connection: Pos. 1: open Pos. 2: closed For engines without oil heating, the selector switch is always open Pos. 2: to lock closed.
5.1.10
ENGINE OPERATION 3.2 Starting
Starting without Cold-Start Aid
3.2.1 Electric Starting Before starting, make sure that nobody is standing in the immediate vicinity of the engine or driven machine. After repair work: Check that all guards have been replaced and that all tools have been removed from the engine. When starting with flame glow system, do not use any other starter substance (e.g. injection with start pilot). Caution: If the speed regulator has been removed, the engine must not be tested under any circumstances: Disconnect the battery. Do not actuate the starter for more than 20 seconds. If the engine does not catch wait a minute then try again. If the engine does not catch after two attempts, refer to the Diagnosis Chart (see 7.1)
with Cold-Start Aid/Flame Glow fr 60=9.5 and 19 volts
Insert key. - Position 0 = no operating voltage Turn key clockwise. - Position 1 = operating voltage - Pilot lights come on. Push the key in and turn further clockwise against spring pressure - Glow plug indicator light comes on - Position 2 = Preheat for approx. 60 seconds (hold key in position)* - Glow plug indicator light goes out - Position 3 = start Release key as soon as engine fires. - Pilot lights go out. * By afterignition in position 2 for up to approx. 3 mins, it is possible to lower further the exhaust gas opacity in the revving-up phase.
Where possible, disengage the clutch to separate the engine from any driven parts. Move speed control lever 1 into idle position.
with Cold-Start/Flame Glow Plug FR 20/30 = 11 and 23 volts
Insert key. - Position 0 = no operating voltage Turn key clockwise - Position 1 = operating voltage - Pilot lights comes on. Push the key in and turn further clockwise against spring pressure - Glow plug indicator light comes on - Position 2 = Preheat for approx. 20-30 seconds (hold key in position)* - Glow plug indicator light goes out - Position 3 = start Release key as soon as engine fires. - Pilot lights go out. * By afterignition in position 2 for up to approx. 3 mins, it is possible to lower further the exhaust gas opacity in the revving-up phase.
5.1.11
Insert key. - Position 0 = no operating voltage Turn key clockwise - Position 1 = no operating voltage - Pilot lights come on. Push the key in and turn it further clockwise against spring pressure - Position 2 = no function - Position 3 = start
with heating pipe
Insert key. - Position 0 = no operating voltage Turn key clockwise - Position 1 = operating voltage - Pilot lights comes on. Push key in and turn further clockwise against spring pressure. - Position 2 = Preheat for approx. 60 seconds (hold key in position)* - Position 3 = Start Release key as soon as engine fires. - Pilot lights go out.
* By afterignition in position 2 for up to approx. 3 mins, it is possible to lower further the exhaust gas opacity in the revving-up phase.
ENGINE OPERATION
3.3 Monitering Systems
3.3.1 Engine Oil Pressure
Oil Pressure Pilot Light The oil pressure pilot light comes on with operating voltage on and engine off.
Oil Pressure Indicator The pointer must remain in the green sector over the entire range.
Oil Pressure Gauge The pointer must indicate the minimum oil pressure (see 9.1).
The oil pressure pilot light should go out when the engine is running.
3.3.2 Engine Temperature
3.3.3 Cooling Fan Drive
Temperature Gauge The engine temperature gauge pointer should remain in the green sector most of the time. It should rarely enter the yellow-green sector. If the pointer enters the orange sector, the engine is overheating. Turn off and establish the cause from the Diagnosis Chart (see 7.1).
If the V-belt rips, pressure pin 1 of the electrical switch is actuated by the tension roller and an acoustic or light signal is given. Switch off the engine immediately to prevent overheating.
5.1.12
ENGINE OPERATION 3.4 Stopping
3.4.1 Mechanical Shutdown
Move speed control lever to low idle. Operate shutdown lever 2 until the engine comes to a stop. The charge pilot light and the oil pressure pilot light will come on when the engine stops. Turn key counter-clockwise (to position 0) and remove. The pilot lights will go out.
3.4.2 Electrical Shutdown
Turn key counter-clockwise (to position 0) and remove. The pilot lights will go out.
Ignition Key
5.1.13
ENGINE OPERATION
3.5 Operating Conditions
3.5.1 Winter Operation Lube Oil Viscosity - Select the oil viscosity (SAE grade) according to the ambient temperature when the engine is started, see 4.1.2 - Increase oil change frequency when operating below -10°C, see 6.1.1 Diesel Fuel - Use winter-grade diesel fuel for operation below 0°C, see 4.2.2 Additional Maintenance Work - Drain the sludge from the fuel tank once a week. (Unscrew the sludge drain plug). - If necessary, allow the oil in the oil bath air cleaner and the engine oil to settle at the ambient temperature. - Below -20°C, after removing the starter if necessary, smear the ring gear on the fly wheel via the pinion bore from time or time with cold-resistant grease, (e.g. Bosch grease FT 1 V 31). Cold-Start Aid - At temperatures near or below freezing point, use glow plugs if necessary, see 3.2.1. This not only lowers the starting limit temperature, but provides easier starting at temperatures normally not requiring a starting aid. Battery - Efficient cold starting requires a healthy battery, see 6.7.1 - The starting limit temperatures can be lowered by 4-5 °C by heating the battery up to about +20°C. (To do so, remove the battery and store in a warm place.)
3.5.2 High Ambient Temperatures High Altitude As the altitude and ambient temperature rise, the density of air tends to decrease, which affects the maximum power output of the engine, the exhaust gas quality and, in extreme cases, the starting behavior. Under transient conditions, the engine can be used at altitudes up to 1000m and temperatures up to 30°C. If the engine is to operate under more severe conditions (at higher altitudes or temperatures), it will be necessary to reduce the injected fuel quality and thus, engine power. If you have any doubts about engine operation under these or similar conditions, ask your engine or equipment supplier whether the engine has been derated in the interests of reliability, service life and exhaust gas quality (smoke). Otherwise contact DEUTZ SERVICE.
5.1.14
OPERATING MEDIA 4.1 Lube Oil
4.1.1 Quality Grade Lube oils are differentiated according to their performance and quality class. In commom use are specifications named after the API (American Petroleum Institute) and ACEA (European Engine OIl Sequences). Approved API Oils: At least:
CF-4
Approved ACEA Oils: At least
E1-96
4.1.2 Viscosity As the viscosity of the lube oil is dependent on temperature, the choice of SAE grade should be governed by the ambient temperature prevailing at the engine operating site. Optimum operating behaviour will be attained if you take the accompanying oil viscosity diagram as a guide. Should the temperature fall temporarily below the limits of SAE grade selected, cold starting may be affected but the engine will not be damaged. In order to keep wear to a minimum, do not exceed application limits for extended periods of time. Oil changes dictated by the seasons can be avoided by using multi-grade lube oils. Multi-grade oils particularly light flowing oils - also reduce fuel consumption.
Oil change intervals, see 6.1.1 Oil capacities, see 9.1
5.1.15
OPERATING MEDIA 4.2 Fuel
4.2.1 Quality Grade Use commercially available diesel fuel with less than 0.5% sulphur content. If the sulphur content is higher than 0.5% oil change intervals should be reduced, see 6.1.1 The following fuel specifications / standards are approved: DIN EN 590 BS 2869: A1 and A2 (with A2, take note of the sulphur content!) ASTM D 975-88; 1-D and 2-D NATO Code F-54 and F-75 Any exhaust emission levels, which may have been determined during type approval tests always refer to the reference fuel prescribed by the authorities for the type approval test.
4.2.2 Winter-Grade Fuel Waxing may occure at low temperatures, clogging the fuel system and reducing engine efficiency. If the ambient temperature is less than 0°C, winter-grade fuel (suitable down to -15°C) should be used. (This fuel is usually available from the filling stations well in advance of the cold months). Diesel fuel containing additives (Super diesel) is often on sale as well, for use down to -20°C. Below -20°C, petroleum must be added. For the required mixing ratios please refer to the adjacent diagram. For artic climate zones down to -44°C special diesel fuels can be used. If summer-grade diesel fuel must be used at temperatures below 0°C, up to 60% kerosene can be added (see diagram). In most cases, adequate resistance to cold can be obtained by adding a flow improver (additive). Please inquire at DEUTZ-PARTNER. Mix in tank only. Fill with the appropriate amount of kerosene first, then add the diesel fuel.
5.1.16
ROUTINE MAINTENANCE
5.1 Maintenance Schedule
5.2 Maintenance Charts The maintenance charts shown here are supplied as self-adhesive labels with each engine. They should be affixed where they can be seen clearly on the engine or driven equipment. Check that this is the case. If necessary, ask your engine or equipment supplier for a fresh supply of labels. Routine work should be carried out according to the schedule in 5.1
Stop the engine before carrying out any maintenance work.
5.1.17
ROUTINE MAINTENANCE
5.3 Completed Maintenance Jobs
5.1.18
SERVICE AND MAINTENANCE 6.1 Lubrication System
6.1.1 Oil Change Intervals The oil change intervals are dependent on the engine application and the quality of the lube oil. If the engine runs fewer hours during the year than stated in the table, the oil should be changed at least once a year. The table refers to the following conditions: - For diesel fuel: sulphur content max. 0.5% by weight. - Continuous ambient temperatures down to -10°C (+14°F) If the sulphur content is > 0.5 to 1% or the continuous ambient temperature below -10°C (+14°F), the intervals between oil changes should be halved. In case of fuels containing more than 1% sulphur, contact your service representative. Change the oil with the engine off but still warm (lube oil temperature approx. 80°C)
6.1.2
Checking Oil/ Checking Engine Oil 6.1.2.1 Checking Oil Level 6.1.2.2 Engine Oil Change
Ensure that the engine or vehicle is in a horizontal position. - Warm Engine: Switch off engine, wait 5 minutes and check the oil level. - Cold Engine: Check oil level. To this end: Remove the oil dipstick.
Ensure that the engine or vehicle is on a level surface. Allow the engine to warm up - Lube oil temperature approx. 80°C. Switch off the engine.
Wipe the dipstick with a non-fibrous, clean cloth. Insert it to the top and remove again. Check the oil level, and if necessary, top up to the “MAX” mark. - If the oil level is only just above the “MIN” mark, more oil must be added. The oil level must not fall below the “MIN” marking.
Place oil tray under the engine. Unscrew drain plug. Drain oil. Fit oil drain plug, with the new gasket and tighten firmly (for torque, see 9.2) Fill with lube oil. - For grade/viscosity, see 4.1 - For quantity, see 9.1 Check oil level, see 6.1.2.1 Be careful when draining hot oil danger of scalds! Do not let used oil run into the soil but catch it in a container ready for proper disposal.
5.1.19
SERVICE AND MAINTENANCE 6.1 Lubrication System
6.1.3 Changing Oil Filter
Undo the filter cartridge using a commercial tool and spin off. Catch any dripping oil.
Beware of burns from hot oil.
Clean any dirt from the filter carrier rim. Lightly oil the rubber gasket of the new oil filter cartridge. Screw in the new cartridge finger tight against the gasket.
6.1.4 Changing the Partail - Flow Oil Filter Insert
Unscrew oil drain plug 1 and drain off oil. Unscrew tension screw 2. Remove the cover. Unscrew the dirtied filter insert 3. Clean the filter housing. Check and if necessary replace cover seal 4. Screw in oil drain plug 1 with new seal 5. Fit new filter insert. Screw on cover and sealing ring 6. Check for leaks and check the oil pressure during a test run.
5.1.20
Tighten the oil filter cartridge with another half-turn. Check oil level, see 6.1.2 Check oil pressure, see 3.3.1 Check cartridge seal for leaks.
SERVICE AND MAINTENANCE 6.2 Fuel System
6.2.1 Changing Fuel Filter
Close fuel stopcock. Undo fuel filter cartridge with commercial tool and spin off. Catch any fuel.
No naked flames when working on the fuel system. NO SMOKING!
6.2.2 Fuel Precleaner Cleaning the Fuel “Bosch” model
Close the fuel shut-off valve. Loosen tensioning nut 2. Swing wire cup 1 to the side. Remove filter cone 5 with strainer 4 and clean in fuel. Use a new seal 3 for filter cone 5. Bleed the fuel system, see 3.1.4
Clean any dirt from the filter cartridge with a final half-turn. Apply light film of oil or diesel fuel to the rubber gasket of the new fuel filter cartridge.
Check for leaks.
Screw in the new cartridge finger tight against the gasket.
Cleaning the Fuel Filter “IMSA” model
Close the fuel shut-off valve. Loosen hexagonal nut 1 and unscrew with sealing ring 2. Remove cover 3. Remove fuel strainer 4.
Check for leaks. No naked flames when working on the fuel system. NO SMOKING!
Tighten the fuel filter cartridge with a final half-turn. Open fuel stopcock.
5.1.21
Clean the fuel strainer 4 in fuel. Replace if necessary. Refit in the reverse order. Bleed fuel system, see 3.1.4 Check for leaks.
SERVICE AND MAINTENANCE 6.3 Cooling System
6.3.1 Cleaning Intervals The amount of contamination in the cooling system depends on the engine Spilled oil or fuel on the engine increases the risk of contamination. Be especially careful if the engine is used in dusty environments. Serious contamination can occur, for example: - on construction sites where there is a high level or air borne dust. - in harvesting applications where here are high concentrations of chaff and chopped straw in the vicinity of the machine. Because applications vary, cleaning intervals have to be determined from case to case. The cleaning intervals given in the table on the right can be used as a guide.
5.1.22
SERVICE AND MAINTENANCE 6.4 Combustion Air Filter
6.4.1 Cleaning Intervals The amount of dirt in the air cleaner depends on the amount of dust in the air and the size of the air cleaner used. If a high level of dust is anticipated, a cyclone-type precleaner can be fitted to the air cleaner. Cleaning intervals will have to be determined from case to case. If dry-type air cleaners are used, they should be cleaned only in accordance with the service indicator or the service switch. Air cleaner servicing is needed when: - Service indicator the red signal 1 is fully visible when the engine is off. - Service switch the yellow pilot light comes on when the engine is running. After carrying out service work, reset the signal by pressing the button on the service indicator.
6.4.2 Emptying Cyclone Type Precleaner
Undo wing nut 1 and remove cover 2. Remove collector bowl 3 from lower section 4 and empty. Clean leaves, straw and other foreign matter from lower section of precleaner. Reposition collector bowl 3 onto lower section 4, fasten cover 2 in place by tightening wing nut 1.
Never fill collector bowl with oil. Replace collector bowl if damaged.
6.4.3 Cleaning Oil Bath Air Cleaner
Turn engine off and wait about 10 minutes for the oil to drain from filter housing 1. Release snap clips 2 and remove oil cup 3 together with filter element 4. If necessary pry element out with a screwdriver, taking care not to damage the rubber gasket 5. Remove dirty oil and sludge. Clean oil cup. Clean filter element 4 in diesel fuel and allow to drip-dry.
5.1.23
Clean filter housing 1 if very dirty. Inspect and replace rubber gasket 5 and 6 if necessary. Fill oil cup with engine oil up to the mark (arrow) (for viscosity, see 4.1.2). Refit oil cup and element to filter housing and secure with snap rings. Never clean air cleaner with gasoline. Dispose of cold oil in accordance with environmental regulations.
SERVICE AND MAINTENANCE 6.4 Combustion Air Filter
6.4.4 Dry Type Air Cleaner Dust Discharge Valve
Filter Cartridges
Empty dust discharge valve 1 by pressing apart lips of discharge slot as indicated by arrows.
Undo clip fasteners 1.
Clean discharge slot from time to time.
Clean cartridge (replace at least once a year).
Remove any caked dirt by pressing together the upper section of the valve. The amount of dirt in the air cleaner depends on the amount of dust in the air and the size of the air cleaner used. If a high level of dust is anticipated, a cyclone-type precleaner can be fitted to the air cleaner.
Take off hood 2 and remove cartridge 3.
Clean cartridge 3. Blow out from inside out with dry compressed air (max. 5 bar), (or in difficult cases, tap out, taking care not to damage the cartridge, or wash according to manufacturer’s instructions. Through regular removal and replacement, the gaskets on the filter cartridge can become damaged. Check paper filter (light showing through) and gaskets for damage. Replace if necessary. After five cleaner services or after two years at the latest, replace safety cartridge 4 (never clean). To do so: - Undo hex. nut 5 and remove cartridge 4. - Install new cartridge, insert and tighten hex. nut. Cleaning intervals will have to be determined from case to case. Install cartridge 3, replace hood 2 and do up clip fasteners 1.
Never clean filter cartridge with gasoline or hot fluids.
5.1.24
SERVICE AND MAINTENANCE 6.5 Belt Drives
6.5.1 Checking V-Belts
6.5.2 Changing the Fan V-Belt
- Carefully remove the gauge without altering the position of the indicator Replace damaged V-belts. arm 1. After installing new belts, run engine for Read off the value where the black 15 minutes, then check belt tension. indicator arm 1 intersects scale 5 To check the tension of the V-belt, use (arrow). For settings, see 9.1 a tension gauge (see 9.3). - Place indicator arm 1 into gauge. - If necessary, retension belt and - Position gauge on V-belt 2, midway measure again. between the pulleys, with flange 3 on bottom of gauge against the edge of belt. Check tension and change belts - Push slowly on the black pad 4 at only with the engine off. Refit right angles to belt 2 until the spring belt guard, if provided. is heard or felt to trigger. Inspect entire V-belt for damage.
6.5.3 Tensioning Alternator Belts
Loosen bolts 1, 2 and 3. Press alternator 4 outwards in direction of arrow A until correct belt tension is achieved. Retighten bolts 1, 2 and 3.
6.5.4 Changing Alternator Belts
Remove fan V-belts as decribed under 6.5.2 Loosen bolts 1, 2 and 3. Swing alternator 4 inwards in direction of arrow B. Remove V-belts and place on new belt. Swing alternator 4 outwards in direction of arrow A until correct belt tension is achieved. Retighten bolts 1, 2 and 3. Fit fan V-belts.
Only check/tension/replace V-belts Retighten new V-belts after 15 minutes running time. when the engine is at standstill. If 5.1.25 necessary, replace V-belt cover.
To replace, press tension roller 1 using a commercial tool and remove the V-belts. Fit new V-belts.
When new V-belts are fitted check the belt tension after ca. 15 minutes running time.
6.5.5 Checking Warning System
If the V-belt rips, pressure pin 1 of the electrical switch is actuated by the tension roller and an acc oustic or light signal is given. Functional check by pressing in pin 1.
Only carry out a check when the engine is at a standstill.
SERVICE AND MAINTENANCE 6.5 Belt Drives
6.5.6 Tensioning and Changing Air Compressor V-Belts
Unscrew hexagonal bolts 1. Remove outer half of belt pulley 2. If necessary replace the V-belts.
To tighten, remove one or more of the inner intermediate discs 3. Place the removed half of the V-belt pulley 2. Retighten bolt 1. While tightening, simultaneously rotate the engine to prevent the V-belt from being crushed. When new V-belts are fitted, check the belt tension after ca. 15 minutes running time.
6.5.7 Air Compressor Design with Doube V-Belt
Screw off hexagonal nut 1, remove V-belt pulley half 2, V-belt 3 and intermediate disc packet 7. Remove intermediate disc 4, rear V-belt 3, intermediate disc packet 6 and V-belt disc half 5. To tighten, remove on or more of the intermediate discs from packet 6 or 7. Place the removed discs in front of or behind V-belt pulley halves 2, so that the V-belt remains aligned. Always take the same number of discs from each packet.
Fit in the reverse order. While tightening nut 1, the engine must be rotated to prevent the V-belts from being crushed. If a V-belt is worn or damaged, both belts in the set must be replaced. The difference in the length of the new V-belts may not exceed 0.15%. Only check or replace V-belts when the engine is at a standstill. If necessary replace V-belt cover. When new V-belts are fitted, check the belt tension after approx. 15 minutes running time.
5.1.26
SERVICE AND MAINTENANCE 6.6 Adjustments
6.6.1 Checking / Adjusting Valve Clearances
Remove the cylinder head cover. Position crankshaft as per schematic Before adjusting valve clearance, allow engine to cool down for at least 30 minutes. The oil temperature should be below 80°C. Check valve clearance 1 between rocker arm / tappet contact face 2 and valve stem 3 with feeler gauge 6 (there should be only slight resistance when feeler blade is inserted). For permissible valve clearance, see 9.1
Adjust valve clearance if necessary: - Release locknut 4. - Use screwdriver 7 to turn setscrew 5 so that the correct clearance is attained after locknut 4 has been tightened. Check and adjust valve clearance on all remaining cylinders. Replace cylinder head cover (use new gasket if needed).
Only inclined engines are fitted with an additional oil jet for lubrication of the bearing. Any adjustments must be carried out in an authorized specialist workshop.
6.6.1.1 Valve Clearance Adjustments Schematic Crankshaft Position 1: Turn crankshaft until both valves in cylinder 1 overlap (exhaust valve about to close, inlet valve about to open). Adjust clearance of valve marked in black on schematic. Mark respective rocker arm with chalk to show that adjustment has been done.
Crankshaft Position 2: Turn crankshaft one full revolution (360°). Adjust clearance of valves marked in black on schematic.
5.1.27
SERVICE AND MAINTENANCE 6.7 Accessories
6.7.1 Battery 6.7.1.1 Checking Battery and Cable Connectors
Keep battery clean and dry. Undo dirty clamps. Clean terminal posts (+ and - ) and clamps of the battery, grease with acid-free and acid-resistant grease. When reassembling, ensure that clamps make good contact. Turn clamp bolts finger tight.
Remove caps 1. If testers 2 are used, the electrolyte should come up to their base. If testers are not used, the electrolyte level should be 10 15mm above the top of the plates. If necessary, top up with distilled water. Replace caps.
The gasses emitted by the battery are explosive! Keep sparks and naked flames away from the battery. Do not allow battery acid to come into contact with skin or clothing. Wear protective goggles. Do not rest tools on the battery.
5.1.28
Measure the electrolyte density of individual cells with a commercial hydrometer. The hydrometer reading (see table on following page) indicates the state of charge. During measurement, the temperature of the electrolyte should preferably be +20°C.
SERVICE AND MAINTENANCE 6.7 Accessories
6.7.2 Three-Phase Alternator
6.7.3 Lifting Tackle
Never disconnect the cable between battery, alternator and regulator while the engine is running. If, however, it is necessary to start and operate the engine without the battery, disconnect the regulator from the alternator before starting. Be sure not to confuse the battery terminals. Replace defective bulb of the charge pilot lamp immediately. When washing the engine, cover up the alternator and regulator. The habit of touching a lead against the frame to check whether it is live must under no circumstances be used with three-phase electrical systems. In case of electric welding connect ground terminal on the welder directly to the piece being welded.
Always use proper lifting tackle 1 when transporting the engine. After transportation and before commissioning of the engine: Remove transport eyes 2.
Use only the correct lifting tackle.
5.1.29
SERVICE AND MAINTENANCE 6.8 Engine Cleaning
6.8.1 Cleaning the Engine With Compressed Air
Switch off the engine. Remove engine covers, cooling-air hoods. Replace following cleaning and before test run. Cover electrical / electronic components / connections (e.g. alternator, starter, regulator, solenoid). Pass compressed air through the engine, being careful with the cooler and cooling fins (start at the exhaust side). Remove dirt which has been blown into the inner compartment.
With Cold-Cleaning Compound
Switch off the engine. Remove engine covers, cooling-air hoods. Cover electrical / electronic components / connections (e.g. alternator, starter, regulator, solenoid). Spray engine with commercial cold-cleaning compound and leave to work for approx. 10 minutes. Spray engine clean with water jet and if necessary repeat procedure.
With High=Pressure Equipment
Switch off the engine. Remove engine covers, cooling-air hoods. Cover electrical / electronic components / connections (e.g. alternator, starter, regulator, solenoid). Clean engine with steam jet (max. spray pressure 60 bar, max. steam temperature 90°C). Drive the engine warm so that remaining water evaporates.
Drive the engine warm so that remaining water evaporates.
The engine may only be cleaned when it is at a standstill.
5.1.30
SERVICE AND MAINTENANCE 6.9 Additional Maintenance
6.9.1 Checking the Mountings
Cylinder head cover 1 Air-intake pipe 2 Coupling sleeves Exhaust line 3 Engine mounting 4
Test Stage 1: Move speed adjustment lever and shut-off lever to “stop” position. Insert key - Position 0 = no operating voltage Turn key clockwise. - Postion 1 = operating voltage - Pilot light comes on. Press in key and turn further clockwise against the spring pressure. - Position 2 = preheat, hold for approx. 1 minute. - Preheat lamp lights up. Otherwise flame glow plug defective or power interrupted.
6.9.2 Checking the Function of the Heating Pipe
When functioning correctly, the heating pipe heats up via the integrated heating coil when starting the preheating - heating pipe - air intake pipe
Test Stage 2:
6.9.3 Checking the Function of the Flame Glowing System
When functioning correctly, intake pipe 4 heats up in the vicinity of flame glow plug 2 when starting with preheating.
Test Stage 3:
Loosen pipe connection 1.
Loosen pipe connection 1.
Rotate engine with starter, key on switch position 3.
Remove flame glow plug 2.
Fuel must be emitted at loosened pipe connection. Otherwise have the system, solenoid 3, checked by a specialist.
Rotate engine with starter, key in switch postition 3. Fuel must be emitted at flame glow plug 2, replace plug 2 as necessary. Use sealant DEUTZ DW 47 when fitting flame glow plug 2. Refit flame glow plug 2 on fuel line. Keep clear of rotating parts. Collect any leaked fuel and dispose of in an environmentally friendly fashion.
5.1.31
FAULTS, CAUSES AND REMEDIES 7.1 Diagnosis Chart
5.1.32
ENGINE PRESERVATION 8.1
If the engine is to remain idle for an extended period of time, it is necessary to take protective measures to prevent rust formation. The preservative measures described here will protect the engine for up to 6 months. The procedure will have to be reversed before the engine is recommissioned. Anti-corrosion oils to specification: - MIL-L-21260B - TL 9150-037/2 - Nato Code C 640 / 642 Recommended cleansing agent to remove preservatives when recommissioning engine: - Petroleum benzine (hazardous materials class A3)
8.1.1 Preserving Engine Clean engine (with cold cleansing agent if preferred) using high pressure equipment. Run engine until warm, then turn off. Drain engine oil, see 6.1.2 and fill with anti-corrosion oil. If necessary, clean oil bath cleaner, see 6.4.3, and fill with anti-corrosion oil. Drain fuel from tank. Make up a mixture of 90% diesel fuel and 10% anti-corrosion oil, and refill fuel tank. Run engine for about 10 minutes. Turn engine off. Turn engine over manually several times to preserve the cylinders and combustion chamber. When rotating with starter, place shut-off lever in stop position. Remove V-belts and store dry in wrapped condition. Spray grooves on V-belts pulleys with anti-corrosion spray.
8.1.2 Removing Engine Preservatives Remove anti-corrosion agent from grooves in V-belt pulleys. Install V-belts. Retension after brief operation if necessary, see 6.5 Remove plugs from intake port and exhaust port. Set the engine in operation.
5.1.33
TECHNICAL SPECIFICATIONS
9.1 Engine Specifications and Settings
5.1.34
TECHNICAL SPECIFICATIONS
9.1 Engine Specifications and Settings
5.1.35
TECHNICAL SPECIFICATIONS 9.2 Torque Wrench Settings
TECHNICAL SPECIFICATIONS 9.3 Tools
The V-belt tension gauge can be obtained under order number 8115 from: COMPANY WILBÄR Postfach 14 05 80 D-42826 Remscheid
5.1.36
ORDERING SPARE PARTS Order information Please specify the following information when ordering original DEUTZ parts. - Engine no. - Ident. no. - Quantity
Document structure
-
The picture diagrams in this spare parts list are sorted according to engine assembly groups.
-
Each section is preceded by an overview of the assembly groups.
-
The ident. no. 08/23 us made up of the assembly group (e.g. 08) and item number (e.g. 23).
5.1.37
ENGINE MAINTENANCE SCHEDULE McL 42 HD
DATE/HRS
SERVICE PERFORMED
5.1.38
BY
NOTES
McL 42 HD
5.1.39
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
DETAIL
PAGE
MACHINE SPLIT COUPLING (PUMP & GEARBOX) HYDRAULIC PUMP COUPLING DOG PLATE THRUST CYLINDER HYDRAULIC CLUTCH PUMP SETTINGS AND ADJUSTMENTS MAIN THRUST VALVE ADJUSTMENT
7.1.1 7.2.1 7.3.1 7.4.1 7.5.1 7.6.1 7.7.0 7.8.0
7.1.0
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
WARNING:
DANGER:
Moving parts. Keep all guards in place. Shut down engine before service or maintenance. Being caught in machinery could cause serious injury.
Crushing weight will cause serious injury. Place machine on solid surface to prevent rollover or falling.
CAUTION:
CAUTION:
Do not modify this machine. Use only authorized McLaughlin repair parts. Failure to comply may result in serious injury. Service this equipment according with maintenance instructions in this manual.
High Pressure. Leaking hydraulic fluid under pressure may penetrate and cause serious injury. Check for leaks with cardboard. Relieve pressure before working on any system.
7.1 Machine Split Instructions 1a
A. Removing the Carriage Important Note: If the jacking station is to be removed from the track, then do the following, in sequence, before removing, the carriage: 1.) Fully retract dog pins. 2.) Close dog pin valve while pins are retracted. 3.) Turn OFF dog pin switch. 4.) Fully retract thrust cylinders. 1.) With the engine OFF, and the key in the OFF position, cycle the thrust valve handle up and down a few times to release any pressure in the system. Disconnect all hydraulic and electrical connections. There are a total of four hydraulic connections and one electrical connection. Use Figures 1 a-e to identify connection points. • Main Thrust Valve - 2 hydraulic connec tions. (Figure 1a) • Track Brake - 1 hydraulic connection (Figure 1b) • Dog Plate - 1 hydraulic connection, 1 electrical connection. (Figure 1c) Install all caps on disconnects.
1b
1c
2.) There are eight bolted connection between the jacking station and carriage. Four bolts fasten vertically and four bolts fasten horizontally. Loosen and rotate the carriage hold down bolts out of their carriage slots.. (Figure 1d) 3.) Use the four lifting eyes on the roll bars to raise the carriage out of the jacking station. DO NOT LIFT THE CARRIAGE AT ANY OTHER POINT EXCEPT BY ALL FOUR LIFTING EYES. The weight of the
7.1.1
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
carriage is not evenly distributed. Use caution when lifting. Make sure all hoses and wires are free from machine components before separating the machine. Place the carriage on a flat and stable surface.
1d
B. Removing the Casing Pusher 1.) The casing pusher has four bolted connections. Loosen, but do not remove the bolts. Rotate the bolts out of the carriage slots. 2.) The casing pusher must be moved far enough horizontally in order to clear the chuck before it can be lifted vertically from the machine.
1e
C. Removing the Jacking Station from Track 1.) The procedures from “Section I - Important Note” must be followed prior to removing the jacking station from the track. 2.) Raise and pin the track hold downs in the retracted position. (Figure 1e) 3.) Use the four lifting eyes in the jacking station to lift the jacking station out of the track. The weight of the jacking station is not evenly distributed. Use caution when lifting. 4.) Place the jacking station on a flat and stable surface. D. Assemble Carriage to Jacking Station 1.) Verify all hoses and wires are free from being pinched or crushed when placing the carriage into the jacking station. Be careful not to damage machine components when placing the carriage. 2.) Once the carriage is resting in the jacking station, fasten the four horizontal bolts first. This will secure the carriage front plate against the jacking station’s thrust wall. Now fasten the four vertical bolts. 3.) Make the four hydraulic and one electrical connections. 4.) Fully open dog pin valve. 5.) Lower and pin the track hold down in the engaged position.
7.1.2
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
7.2 Coupling Instructions Tools Required: - 5/8” hex bit socket and ratchet - 1 1/8” socket or wrench - 3/16” Allen-head T-handle wrench - McLaughlin Tool #4810321 1. REMOVAL Remove the coupling guard from mounted position on the transmission. Remove the two bolts that fasten the coupling hub to the coupling. Loosen the set screw over the key in the coupling hub. Slide the coupling hub up the input adapter shaft to create enough clear ance for removing the coupling center member. Next, fit McLaughlin tool #4810321 onto the companion flange. Use this tool to prevent the transmis sion form rotating when removing the last two bolts of the coupling center member.
II. INSTALLATION Install the coupling hub onto the input adapter shaft. Install the coupling center member into its’ respective pilot holes on the coupling adapter plate. Fit McLaughlin tool #4810321 onto the companion flange and then tighten the two botls to 225 ft-lbs. Slide coupling hub onto the pilots of the coupling center member. Tighten the two bolts to 225 ft.lbs. Tighten the set screw over the key. Install the coupling guard.
7.2.1
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
7.3 Hydraulic Pump Coupling Assembly
Alignment Loosen, but do not remove the 4 screws that attach the pump adapter plate to the pump mount. Adjust the pump plate until the nylon sleeve on the coupling slides freely. Tighten the 4 screws. (Fig. 1-c) Disassembly/Assembly D1. Remove the screw for the pump and pull the pump out of the adapter plate. Do not remove the 4 screws which attach the adapter plate to the pump mount. D2. Loosen the coupling cross-clamp and remove the coupling from the pump shaft.
A1. Pilot the adapter plate to the engine crankshaft pulley. Make sure that all hoses are properly lined up and that the adapter is sitting flush against the pulley. Apply Loctitie #271 to the screws and tighten the screws in an alternating circular pattern. A2. Pilot the coupling hub into the adapter. Make sure that the coupling is sittling properly on the face of the adapter. Apply loctite #271 to the screws andtighting the screws in an alternating pattern. A3. Install the nylon sleeve onto the coupling. A4. Install the pump coupling onto the pump
D3. Remove the nylon sleeve. D4. Remove the screws that attach the coupling hub to the adapter plate and remove the coupling hub.
Adapter Plate
Pump Coupling
Nylon Sleeve
7.3.1
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
Dog Pin Indicator Detail Some items not shown for clarity.
7.4 DOG PLATE Dog Pin Indicators - The dog pin indicator lights should come on when the dog pins are retracted and go off when the dog pins are fully extended. Adjust the switches so the lights give an accurate indication of the dog pin position. Sometimes the dog pin may be in a bind and may not be able to extend fully. Check that the dog pins are working freely before making any adjustments. Make sure that the dog pin valve is open enough (5-6 turns) for the pins to move freely. Dog Pin Indicator Switch Adjustment 1. Extend the dog pins. 2. Remove the top plate on the dog plate cover box. 2. Turn the ignition switch to the “ON” position and note dog pin positions and dog pin indicator lights. 3. The switch brackets allow for adjustment forward and backward, and side to side. Loosen, but do not remove the screws which will allow movement in the required direction for proper switch placement. Note: The switch should be positioned with “DIM A” = 1/4”-3/8” air gap between the switch arm and the hydraulic dog plate cylinder. Refer to the illustration above. 4. Tighten the screws and test the operation by repeatedly extending and retracting the dog pins. Repeat these steps if further adjustments are necessary.
7.4.1
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
Dog Plate Adjustable Valve
Dog Plate Cylinder Replacement D1. Open the dog pin valve completely. D2. Remove the top plate of dog plate box. D3. Disconnect and cap the hydraulic hose at the cylinder swivel fitting. D4. Remove the two screws that attach the cylinder to the dog pins. The dog pins are spring loaded, so there will be pressure on the screws when they are removed. Note: Be careful not to damage machine components still in place, wires, switches, etc. D5. It is recommended that the dog plate be thoroughly cleaned whenever the dog plate cylinder is removed. D6. Remove the dog pins and dog pin springs. Clean the dog pins and remove any rust or corrosion on the pins. Clean any mud or dirt out of the springs. Replace springs if necessary. Clean the dog plate housing. Make sure the dog pins can slide freely in and out by hand, before reassembling. A1. The dog pin has a top and a bottom. The top of the dog pin is determined by the depth of the set screw in the tapped hole. The top of the dog pin has a set screw depth of ~ 5/16”. If this dimension is not correct, adjust the set screw. Remove the set screw and clean off any residual thread lock. Clean the tapped hole in the dog pin. Apply Loctite #243 to the set screw and insert it into the dog pin to the proper depth. Allow the thread lock to cure before reassembling.
7.4.2
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
A2. Insert the dog pin springs into the dog plate. Make sure the springs slide over the center pin and are seated on the stop in the center of the housing. A3. After the dog plate and pins have been cleaned, apply a thin film of oil to the pins and insert them into the dog plate. Do not use grease or heavy oils. These heavier lubricants tend to attract dirt more than lighter oils. A4. Press the dog pins into the housing until the tapped holes in the dog pins are accessable in the slots in the top plate. A5. Put the cylinder screws through the cylinder end lugs and thread the screws into the dog pins. Tighten the screws until they bottom out on the set screws in the dog pins. Once tight, there should be a small gap between the base of the cylinder and the dog plate. The gap keeps the cylinder from pulling the dog pins against the top of the dog plate. Note: The cylinder must be positioned properly to match up with the dog pin indicator switches. A6. Connect the hose to the dog plate cylinder swivel fitting. A7. Operate machine and check for leaks. A8. Replace the top plate. Dog Plate Cylinder Seal Kit Replacement D1. Remove cylinder as described in the above section. D2. Remove the swivel fitting and unscrew the threaded cap. NOTE: FLUID UNDER PRESSURE. THERE MAY BE REMAINING HYDRAULIC FUILD IN THE CYLINDER. EXTENDING OR RETRACTING THE CYLINDER CAN FORCE FLUID OUT OF THE CYLINDER. FLUID UNDER PRESSURE CAN CAUSE SERIOUS INJURY. D3. Pull the rod assembly out of the barrrel. D4. Remove the piston from the end of the rod assembly. D5. Remove the threaded cap from the rod assembly. D6 Remove and discard all seals, o-rings, back-up washers and wipers. Visually note the placement and orientation of all seals before removal. A1. Clean all components with brake cleaner and let dry. A2. Refer to the Dog Plate Cylinder Components section of this manual for proper seal placement and orientation. Lube all seals and wipers with a thin coat of oil before assembly. A3. Install the threaded cap onto the rod assembly, note proper orientation. A4. Install the piston onto the rod assembly. A5. Insert the rod assemlby into the barrel. A6. Tighten the threaded cap. A7. Refer to Dog Plate Cylinder Replacement instructions for assemlby procedure.
7.4.3
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
THRUST CYLINDER Removal: D1. Remove the carriage from the jacking station. D2. Disconnect and cap the hydraulic hoses and cylinder ports. D3. Disconnect the hydraulic and electrical connections at the dog plate. D4. Remove the 3 cylinder pins in the dog plate and slide the dog plate away from the cylinders. D5. Remove the cylinder from the jacking station. Note: Be careful not to damage machine components already in place.
Thrust Cylinder Seal Kit Replacement: D1. Remove the rod clevis. D2. Remove the rod-end base plate. D3. Unscrew the rod end cap. D4. Pull the rod assembly out of the barrel. D5. Remove the piston from the end of the rod assembly. D6. Remove and discard all seal and wipers. Visually note the placement and orientation of all seals before removal. A1. Clean all components with brake cleaner and let dry. A2. Refer to the Thrust Cylinder Components section of this manual for proper seal placement and orientation and torque requirements for fasteners. Lube all seals with a light coat of oil before assembly. A3. Install the piston on the rod assembly and torque the retaining nut to the proper specifications. A4. Insert the rod assembly into the barrel. A5. Install the rod end cap and torque to the proper specifications. A6. Install the rod end plate and torque screws to the proper specifications. A7. Position the cylinder in the jacking station and reinsert the cylinder pin. A8. Position the dog plate on the cylinders and insert the dog plate cylinder pins. A9. Connect the hoses. A10. Connect the hydraulic and electrical connections at the dog plate. A11. Install the carriage. A12. Operate the machine and check for leaks.
7.5.1
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
7.6 CLUTCH SERVICE Disassemble for Disc Change:
7.6.1
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
Assemble for Disc Change:
7.6.2
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
Disassemble Clutch:
7.6.3
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
Assemble Clutch:
7.6.4
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
7.7 PUMP SETTINGS AND ADJUSTMENTS This machine is equiped with a pressure compensated, hydraulic piston pump with load sense. It has two adjustable settings, Compensator pressure setting and Stand-by pressure setting. Refer to the Specifications and Settings section of this manual for those settings. The case ports are identified by the following marks: Inlet Port (suction) : Right side of pump (facing the front of the machine) Outlet Port (pressure) : Left side of pump (facing the front of the machine) Load Sense Port: Top center of pump, marked “X”. Case Drain Port: Top center of pump, marked “L2”. Gauge Port (system pressure) : Bottom side of pump, marked “M2”.
Stand-by Pressure Adjustment
Compensator Adjustment
Pump Setting Detail
7.7.1
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
Setting the Stand-by Pressure ~ 250-300 psi (17.5 - 20.7 bar) * Remove and cap 2nd system to read only, pop stand-by pressure. The Stand-by pressure setting, is set by adjusting the top set screw on the top-center of the pump case. 1. Install a 0-5000 psi minimum pressure gauge into the gauge port on the pump. 2. Start the engine. The pressure on the gauge is the current stand-by pressure setting. 3. Loosen, but do not remove, the locking set screw in the side of the adjustment housing. 4. Adjust the set screw in the center of the adjustment housing until the desired pressure is acheived. 5. Tighten the locking set screw. 6. Check pressure setting. Setting the Compensator ~ 5000 psi (344.8 bar) The Compensator pressure setting is set by adjusting the bottom set screw on the top-center of the pump case. 1. Install a 0-5000 psi minimum pressure gauge into the gauge port on the pump. 2. Start the engine and retract the cylinders using the manual lever on the thrust control valve. 3. Dead-head the cylinder in the retracted position and the pressure on the gauge is the compensator setting. 4. Loosen, but do not remove, the locking set screw in the side of the adjustment housing. 5. Adjust the set screw in the center of the adjustment housing until the desired pressure is acheived. Dead-head the cylinders and make an adjustment. Release the cylinders and allow the pump to drop to stand-by pressure before making more adjustments. Do not try to adjust the pump all at one time. 6. Tighten the locking set screw. 7. Check pressure setting. NOTE: There are no other adjustable functions on this pump. If the pump requires more service, consult the McLaughlin Manufacturing Co. for pump service and repair instructions.
7.7.2
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
7.8 Main Thrust Valve Adjustment The main thrust valve has both a manual control lever, and an electric solenoid control. The electrical control portion is covered under the Autobore section. The valve has an adjustable relief valve built in. It is preset at the factory and should not require adjustment in the field. Reference the Components section for valve handles. Relief Valve Adjustment ~ 5100+ psi (351.7 + bar) The relief valve is located just below the instrument panel. Raise the instrument panel to access the relief valve. 1. Install a 0-5000 psi minimum pressure gauge into the gauge port on the pump. 2. Start the engine and confirm that the compensator is set at the proper setting. Note: the relief valve is set 100-200 psi (6.9 - 13.8 bar) above the compensator setting. If the compensator setting is wrong, the relief valve setting will be wrong. 3. Remove the locking cap. 4. Loosen, but do not remove the locking nut on the relief valve. 5. Loosen the relief valve threaded stud 1-2 turns. 6. Run the machine and collapse the thrust cylinders using the manual lever on the valve. 7. Dead-head the cylinders in the retract position and adjust the relief valve until the engine relieves its self. Adjustment of this valve is an audible determination. When the pump goes over relief it continues to pump oil which lugs the engine down. When the pump reaches proper compensator setting and de-strokes, the relief valve is set properly. 8. After the pump de-strokes, turn the relief valve threaded stud 1/4 of a turn and tighten the lock nut. 9. Install the locking cap. 10. Replace and secure the instrument panel.
7.8.1
WARRANTY & RETURN GOODS POLICY LIMITED WARRANTY The Manufacturer warrants its products to be free from defects in material and workmanship for a period of twelve months from the date of shipment from the factory. Hole Hammer pistons, bodies, and nose pieces are warranted to be free from defects in material and workmanship for a period of three years from the date of shipment from the factory. The Manufacturer shall not be responsible for any damage resulting to or caused by its products by reason of installation, improper storage, unauthorized service, alteration of the products, neglect or abuse, or use of the product in a manner inconsistent with its design. This warranty does not extend to any component parts not manufactured by Manufacturer; however, Manufacturer’s warranty herein shall not limit any warranties made by manufacturers of component parts which extend to Buyer. Claims for defects in material and workmanship shall be made in writing to Manufacturer within ten days of discovery of defect. Manufacturer may either send a service representative or have the product returned to its factory at Buyer’s expense for inspection. Upon notification of defect, Manufacturer will issue a return goods authorization number to Buyer. The return goods authorization number must accompany the product returned. If judged by the Manufacturer to be defective in material or workmanship, the product will be replaced or repaired at the option of the manufacturer, free from all charges except authorized transportation. Buyer shall be responsible for all maintenance services consisting of lubrication and cleaning of equipment, replacing expandable parts, making minor adjustments, and performing operating checks, all in accordance with procedures outlined in Manufacturer ’s maintenance literature. THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES AND NO REPRESENTATIONS, GUARANTEES, OR WARRANTIES, EXPRESS OR IMPLIED, (INCLUDING BUT NOT LIMITED TO A WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), ARE MADE BY THE February 8, 2005
MANUFACTURER IN CONNECTION WITH THE MANUFACTURE OR SALE OF ITS PRODUCTS. NO EMPLOYEE, DISTRIBUTOR, OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THIS WARRANTY ON BEHALF OF MANUFACTURER THE REMEDIES OF BUYER SET FORTH HEREIN ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER REMEDIES. THE LIABILITY OF MANUFACTURER WHETHER IN CONTRACT, TORT, UNDER ANY WARRANTY, OR OTHERWISE SHALL NOT EXTEND BEYOND ITS OBLIGATION TO REPAIR OR REPLACE, AT ITS OPTION ANY PRODUCT OR PART FOUND BY MANUFACTURER TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP. MANUFACTURER SHALL NOT BE LIABLE FOR COST OF INSTALLATION AND/OR REMOVAL OR BE RESPONSIBLE FOR DIRECT, INDIRECT, SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY NATURE. GENERAL RETURNS OF MERCHANDISE 1. All returns must be pre-authorized A. Please call our parts department for an RGA number B. Please include RGA number on the outside of box C. Include any required paper work or special instructions D. Items returned without an RGA number will not be accepted 2. All returns are subject to a 20% restock charge. 3. Special items are non-returnable A. Non-stock parts B. Custom parts C. If you are unsure about a parts status when ordering, ask your McLaughlin representative if the item fits on of the above conditions. 4. Items must be returned within thirty days of original order date. 5. Items not returned within 30 days from the date of RGA is issued will not be accepted. 6. The item(s) must be in new condition. Used item(s) are not returnable.
MODEL MCL 42 HD EARTH BORING MACHINE MACHINE SERIAL NO.: 3642HD05040604 & LA TER LATER MANUAL
PART
NO.:
E250400
Machine Serial #_________________________________________________________ Purchased & Serviced Thru: __________________________________________________________ Purchase Date: _________________________________________________________ © 2003 by McLaughlin Group, Inc.
All rights reserved. No part of this manual may be reproduced in any form or by any means without prior written permission from McLaughlin Group, Inc.
Revision Date: DEC 2006
WARNING: Battery posts, terminals and releated accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.
WARNING:
The engine exhaust from this product contains chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.
TABLE OF CONTENTS McL 42 HD
DESCRIPTION
PAGE
Machine Specifications and System Operating Specifications
1.1.0
Fill Points, Filters and Routine Maintenance Decal Placement
2.1.0 2.2.0
Machine Assemblies, Parts Details Jacking Station Assembly Carriage Assembly Roll Bar Assembly Powertrain Assembly Dog Plate Assembly Casing Pusher Assemblies & Adapters Track Assembly Hydraulic Tank Assembly Fuel Tank Assembly
3.0 3.1.0 3.2.0 3.3.0 3.4.0 3.5.0 3.6.0 3.7.0 3.8.0 3.9.0
Machine Operating Systems Hydraulic System (Hoses and Fittings) Electrical System (Wiring Diagram)
4.0 4.1.0 4.2.0
Machine Component Parts Details Engine (Operation and Parts) Gearbox (Parts) Transmission (Parts) Hydraulic Pump Coupling Hydraulic Clutch Hydraulic Thrust Cylinder Hydraulic Dog Plate Cylinder Hydraulic Valve (Parts)
5.0 5.1.0 5.2.0 5.3.0 5.4.0 5.5.0 5.6.0 5.7.0 5.8.0
Hydraulic Clutch Operation Troubleshooting
6.0 6.1.0 6.2.0
McLaughlin Group, Inc. reserves the right to make changes at any time without notice or obligation.
TABLE OF CONTENTS McL 42 HD
DESCRIPTION
PAGE
Service and Repair Instructions Machine Split Coupling (Transmission/Gearbox) Hydraulic Pump Coupling Dog Plate Cylinder Hydraulic Clutch Pump Settings and Adjustments Main Thrust Valve
7.0 7.1.0 7.2.0 7.3.0 7.4.0 7.5.0 7.6.0 7.7.0 7.8.0
Deutz Emission Warranties
Insert
McLaughlin Group, Inc. reserves the right to make changes at any time without notice or obligation.
MACHINE SPECIFICATIONS McL 42 HD
SPECIFICA TIONS OF MCL 42 HD SPECIFICATIONS EARTH BORING MACHINE Boring Range:
ENGLISH
METRIC
Cased Bore
16”-42”
41 cm-107 cm
Engine: Air cooled, in-line 4 cylinder diesel, turbo charged 12 VDC electric system 106 hp ISO max. (79 kW) @ 2,500 RPM 96 hp continuous (72 kW) @ 2,500 RPM
Transmission: 5 forward speeds, 1 reverse Clutch: Hydraulic clutch with Operator Presence Control Switch Final Drive: Planetary reduction, 4” hex chuck (10 cm) Auger Torque: 113,500 ft/lbs. peak(153,900 Nm) in 1st gear Forward Thrust: 633,333 lbs. (2817 kN) max @ 5,000 psi (345 bar) with infinitely adjustable thrust speed
Dog Plate: Hydraulically activated with dog pin indicators Hydraulic Parameters: 5,000 psi (345 bar) max. system, pressure comp. pump with load sense, 48 gpm (182) lpm @ 2,500 RPM, hydraulic tank capacity 52 gallons (198 L), oil level sight gauge, temp. and cleanout ports.
Hydraulic Filtration:
1. Suction strainer - 100 mesh 2. In-take return filter - 12 micron replaceable element 3. 10 micron spin-on return filter
Fuel Tank: 11 gallon (41.5 L) capacity with sight gauge
Dimensions/Weights Machine: 68” (173 cm) wide x 12’ ( 3.6 m) long x 68” (173 cm) high Jacking Station: 5,200 lbs. (2,360 kg) Carriage: 6,650 lbs. (3,017 kg) Casing Pusher: 1,150 lbs. (522 kg)
Track: 60 1/2” (154 cm) wide x 9’ (274 cm) long x 14.5” (37 cm) high - 1,400 lbs.(635 kg) 5’ (152 cm)Track Extension: 750 lbs. (341 kg) Machine Centerline: 29 3/8” (75 cm) Push Plate: 440 lbs. (200 kg) McLaughlin Group, Inc. reserves the right to make changes at any time without notice or obligation.
1.1.1
SYSTEM OPERATION SPECIFICATIONS McL 42 HD
Engine 1. Speed 2. Oil 3. Fuel 4. Fuel Tank Capacity
Idle: 1050-1150 Max.: 2400-2500 SAE 5W-30 or refer to Engine Manual Commercially available diesel fuel with less than 0.5% sulphur content. Refer to Engine Manual. ~ 15 Gallons (56 l.)
Gearbox Capacity
80-90 wt. gear oil with EP additives ~ 2 Gallons (8 l.)
Transmission Capacity
Synthetic 50 wt. transmission fluid 1.5 Gallons (5.9 l)
Hydraulic System 1 Hydraulic Pump 2. Hydraulic Control Valve Main Thrust Sysem
Pressure Compensated w/ Load Sense Compensator Setting: ~ 5000 psi Stand-by Setting: ~ 250-300 psi Electric-proportional w/ Manual operation Relief Valve Setting: ~ 5100 + psi
3. Hydraulic Track Brake (Secondary System)
Setting: ~ 800 psi
4. Hydraulic Dog Pins (Secondary System)
Setting: ~ 800 psi
5. Hydraulic Clutch (Secondary System)
Setting: 225 psi
6. Hydraulic Fluid:
76 Unax AW #46 or equivalent ISO grade 46, hydraulic fluid with anti-wear additives. Contains additives that provide oxidation resistance, rust and corrosion protection, foaming resistance and have water separating characteristics. Consult McLaughlin Group, Inc. for recommendations on cold weather operation.
7. Hydraulic Tank Capacity
~ 50 Gallons (189 l.)
Electrical System 1. Battery 2. Hydraulic Control Valve Main Thrust System 3. Preheat System 4. Fuses 5. Cartridge Valves
12V DC w/ 700 CCA Max. 12V DC w/ Valve Driver Card and Potentiometer .6 Amps to shift valve, 1.8 Amps to shift fully 12 V DC w/ manual delay 12V DC, Inline and panel, SFE and ATO styles 12V DC at 1-3 Amps
*Specifications subject to change without notice or obligations.
1.1.2
FILTERS AND FILL POINTS McL 42 HD
1
1. Engine Oil Fill - Use only manufacturer’s approved oils (Reference section 5.1 Engine Operation).
2
2. Dip Stick - Check daily with engine warm. Fill as needed to the upper dash mark on the stick.
3. Oil Filter - Use only manufacturer approved engine filter. Reference section 5.1 Engine Operations for specifications and maintenance.
3, 4
4. Fuel Filter - Use only manufacturer’s approved replacement filters. (Reference section 5.1 Engine Operation for maintenence schedule).
5
5. Fuel Level - Fill as needed with branded grades of diesel fuel with a sulfur content below 0.5% (Reference section 5.1co Engine Operation for approved fuel specifications).
2.1.1
FILTERS AND FILL POINTS McL 42 HD
6
6. Hydraulic Oil Level - Fill to 1 1/2” below top of tank (with cylinders retracted). Change oil after first 1000 hours of use, then annually.
7
7. Hydraulic Oil Filter - Replace all filters with every engine oil change or if required by filter indicator, whichever comes first. Clean or replace in-tank suction strainer annually when oil is changed.
8. Gearbox Oil Fill - Fill to check point. Change after first 50 hours of use, then every 1000 hours or annually.
8
9. Transmission Oil Fill - Fill to check point with #50 synthetic transmission fluid. Change after first 50 hours of use, then every 1000 hours or annually.
9 10. Engine Air Cleaner - Check air cleaner element condition using the filter indicator. Clean or replace element when indicator is in the “red zone.” Clean or replace when required by the filter indicator or annually, which ever comes first. Reference pages 5.1.23 & 5.1.24 of the Engine Operation section for more information.
2.1.2
DECAL APPLICATION: REMOVE OIL AND DIRT FROM SURFACE. MAKE SURE SURFACE IS SMOOTH.
2.2.1
PLACE ON MANUAL BOX
J800030 - INSTRUCTION OPERATOR’S MANUAL
J000080 - WARNING DO NOT GO FORWARD
J000020 - WARNING AVOID DEATH
J000210 - WARNING LOCATE UTILITIES
J000100 - DANGER ENTANGLEMENT HAZARD
DECAL PLACEMENT McL 42 HD
2.2.2
J000080 - WARNING DO NOT GO FORWARD
J000200 - DANGER MACHINE PARTS
J000120 - DANGER ROTATING BLADES
J802000 - WARNING ROTATING SHAFT
J000160 - CAUTION PINCH POINT 2 REQUIRED
DECAL PLACEMENT McL 42 HD
JACKING STATION ASSEMBLY McL 42 HD
3.1.1
JACKING STATION ASSEMBLY McL 42 HD
ITEM# 1 2
3
4
5
6
7
QTY. 1 4 4 4 4 8 8 4 4 4 1 1 1 4 4 1 2 1 1 4 4 4 4 4 1 4 4 4 1
NUMBER 4210101 4810129 4810134 U001583 4810130 4800147 U340065 W000100 U001581 U210071 4801110 4801111 4801113 U210100 U000820 4801112 U000080 W200215 4801114 U210060 U000420 4800149 4810134 U001583** 4210130 U000440 U200600 U210060 E 250210
DESCRIPTION Jacking Station Anchor Pin Heavy Duty Washer Screw, HC 1-8 x 6.50 G8** Hold Down Hold Down Pin .25" Linch Pin Cam Roller Screw, HC 1.25-7 X 5.50 ZP Nut, Lock NY 1.25-7 Track Brake Assembly Track Brake Cylinder Carrier Mounting Block Washer, Lock .500 Screw, HC .500-13 X 1.25 G5 Piston Screw, HC .250-20 X 1.25 G5 O-Ring #236 Stop Plate Washer, Lock .375 Screw, HC .375-16 X 1.00 Carriage Pin 1/2' Heavy Duty Washer Screw, HC 1-8 X 6.50 G8 Quick Disconnect Mount Screw, HC .375-16 X 1.25 G5 Washer, Flat .375 Washer, Lock .375 Safety Manual Box (Not Shown)
** - Use exact grade specified - DO NOT change from original equipment.
3.1.2
CARRIAGE ASSEMBLY McL 42 HD
3.2.1
CARRIAGE ASSEMBLY McL 42HD
ITEM # 1 2
3
4
5
6
QTY. 1 1 4 8 1 3 6 6 1 4 4 1 2 2 2 1 1
NUMBER 4210201 4210701 4800762 U120200 4210219 4800277 U200060 U100060 4810270 U000820 U210111 4810277 U000180 U210040 U200060 X 400030 X 400020
DESCRIPTION Carriage Hydraulic Tank Hydraulic Tank Mount Nut, Hex .375-16 Fuel Tank Fuel Tank Mount Washer, Flat .375 Nut, Hex .375-16 Battery Bracket Screw, HC .500-13 X 1.25 Washer, Lock .500 Battery Hold Down Screw, HC .312-18 X .75 Washer, Lock .312 Washer, Flat .375 Battery Enclosure Battery Automotive
3.2.2
ROLL BAR ASSEMBLY McL 42 HD
3.3.1
ROLL BAR ASSEMBLY McL 42 HD
ITEM# 1
2
3
4 5
6
7
QTY. 1 16 16 16 1 12 12 12 1 4 4 4 1 1 1 1 4 8 12 8 2 4 1 4 4 4 1 1 2 2 2 1 1 1 1 1 1
NUMBER 4210230 U001420 U210160 U100200 4810232 U000860 U200100
DESCRIPTION Ro ll Cag e Scre w, HC .750-10 X 2.50 Washe r, Lo ck .750 Nut, He x .750-10 Pump Ro ll Cag e Scre w, HC .500-13 X 1.75 Washe r, Flat .500
U100120 4210250 U000820 U210100 U100120 4800288 4800299 4800298 4800297 4800290 U000817 U200100 U210100 4800295 U120200 4210264 U000040 U210020 U200020 4801300 4801301 U200040 U210040 U000160 4801333 2050057 U000220 U210040 U200040 U210041
Nut, He x .500-13 To o lb o x Scre w, HC .500-13 x 1.25 Washe r, Lo ck .500 Nut, He x .500-13 Mirro r Bracke t Mirro r Le ft Sid e Muffle r Bracke t Rig ht Sid e Muffle r Bracke t Muffle r Iso lato r Scre w, HC .500-13 X 1.00 G8 Washe r, Flat .500 Washe r, Lo ck .500 Muffle r Ho o k Nut, Whiz, Lo ck Op e rato r Co nso le Scre w, HC .250-20 X .750 Washe r, Lo ck .250 Washe r, Flat .250 Drag Brake Hand le Asse mb ly Drag Brake Hand le Bracke t Washe r, Flat .312 Washe r, Lo ck .312 Scre w, HC .312-18 X .500 Le ve r Le ve r Grip Scre w, HC .312-18 X 1.25 Washe r, Lo ck .312 Washe r, Flat .312 Nut, Nylo ck .312-18
ITEM#
QTY.
8
1 4 4 4 1 1 1 1 1 1 1 4 1 1 3 3 3
9
10
NUMBER
DESCRIPTION
4210262 U000040 U200020 U210020 4800784 4800829 X000400 3600116 3600115 3600131 4800778 U030110 4810710 4210211 U000817 U210100 U200100
Co nso le Co ve r Plate Scre w, HC .250-20 X .750 Washe r, Flat .250 Washe r, Lo ck .250 Pre ssure Gaug e , 5000 p si Po we r Outle t Tacho me te r, Op e rato r Switch Thro ttle Co ntro l Thro ttle Cab le Thro ttle Cab le Bulkhe ad Ad ap te r Co ntro l Valve Scre w, SFH .437--14 X 1.25 Valve Hand le Valve Ad ap te r Plate Scre w, HC .500-13 X 1.00 G8 Washe r, Lo ck .500 Washe r, Flat .500
Optional Equipment (Available upon request) 1
3.3.2
1
4810281
Vand al Shie ld , Co ntro l Pane l
POWERTRAIN ASSEMBLY McL 42 HD
3.4.1
HYDRAULIC PUMP DETAIL
POWERTRAIN ASSEMBLY
HYDRAULIC PUMP DETAIL
McL 42 HD
ITEM #
QTY.
NUMBER
DESCRIPTION
1 2
1 1 1 1 1 1 1 1 1 1 1 3 3 3 1 2 4 1 1 1 1 1 1 1 1 1
4210302 4800324 U001590 4801108 U024010 4800328 3600131 3600115 4800365 4800379 4800364 U000802 U210080 U100100 4800384 4800341 U120205 4800368 4800381 4810308 4800378 4210317 4200041 4210315 4210316 4800338 480033801 480033802 480033803 48100310 48100311 U001642 U001646 U210223 4800212 4800215 U001642 U210223 4800352 U001020 U000806 U200100 U120120
20 913 4 Cylind e r De utz Eng ine Thro ttle Cab le Arm Scre w, HC 8mm X 1.25 X 15mm Cab le Lo ck Scre w, Se t .250-20 X .500 KN Cup Bracke t, Cab le Bulkhe ad Bulkhe ad Ad ap te r Kit Thro ttle Cab le Shut Do wn So le no id Exhaust Se al Ring s 21 Exhaust Manifo ld Elb o w 22 Scre w, HC .438-14 X 2.250 23 Washe r, Lo ck .438 Nut, He x .438 24 Exhaust Fle xib le Ho se Muffle r Exhaust Bracke t Nut, Whiz, Lo ck .312-18 Exhaust Muffle r Sid e 25 Muffle r Muffle r Exhaust Elb o w Raincap Air Cle ane r Elb o w Air Filte r Ind icato r Air Cle ane r Intake Tub e Air Cle ane r Ad ap te r Air Cle ane r Air Cle ane r Cap Air Cle ane r Oute r Filte r Ele me nt Air Cle ane r Inne r Filte r Ele me nt R.S. Eng ine Mo unt We ld me nt L.S. Eng ine Mo unt We ld me nt Scre w, HC 12mm X 1.75 X 30 Scre w, HC 12mm X 1.75 X 45 Washe r, Lo ck 12mm R.S. Re ar Eng ine Mo unt L.S. Re ar Eng ine Mo unt Scre w, HC 12mm X 1.75 X 30 Washe r, Lo ck 12mm Eng ine Iso lato rs Scre w, HC .500-13 X 5.50 Scre w, HC .500-13 X .75 Washe r, Flat .500 Nut, Lo ck .500-13
3
4 5 6
7 8 9 10 11 12 13 14 15 16
17
18
19
1 1 4 4 8 1 1 8 8 4 4 8 12 12
3.4.2
1
1 1 1 4 1 1 3 4 1 4 4
4800351 Due tz P/N 030-3808 030-3807 030-3809 223-9180 030-3795 336-3948 111-2322 111-1244 4800360 4210308 4800701 111-2322 4800702 U001485 U001420 U210160 4800769 U210100 U000900
Fro nt Guard Co ve r Asse mb ly He x Sp ace r Tub e Sp ace r Sup p o rt Bracke t Halte r Bracke t Be lt Guard Washe r HHCS Iso -4017 M8 X 20 A4C HHCS Iso -4014 M8 X 200 A4C Hyd raulic Pump Co up ling Pump Co up ling Ad ap te r Mo unting Plate HHCS ISO-M8 X 20 A4C Pilo t Plate Scre w, HC .750-10 X 3.50 G8 Scre w, HC .750-10 X 2.50 Washe r, Lo ck .750 Hyd raulic Pump Washe r, Lo ck .500 Scre w, HC .500-13 X 2.50
POWERTRAIN ASSEMBLY
TRANSMISSION DETAIL
12
17
18
14
13
16
15
11
19
7
10
9
8
6
5
4
2
3
1
McL 42 HD
3.4.3
POWERTRAIN ASSEMBLY McL 42 HD
ITEM # 1 2
3 4 5
6 7 8 9 10 11 12 13 14 15 16
17 18
19
QTY. 1 1 4 4 5 5 1 3 3 1 1 1 2 1 12 12 1 1 4 1 1 1 1 1 1 1 1 1 1 2 2 4 1 2 2 1 1 2 2 1 6
NUMBER 4800346 4810312 U001360 U210160 U001642 U210223 4810346 U000440 U200600 480034601 480034602 4800369 4810355 4000335 U001620 U210220 4810322 4800844 8030438 4800336 4810385 4810379 4810399 4810398 4810382 4800387 4810384 4801345 4800841 U000060 U000020 U210020 4800371 U210240 U210220 X000047 4801309 U000040 U200020 4810389 U030050
TRANSMISSION DETAIL
DESCRIPTION Transmission Transmission Support Weldment Screw, HC .750-10 X 1.50 Washer, Lock .750 Screw, HC 12mm X 1.75 X 30mm Washer, Lock 12mm Coupling Guard Screw, HC .375-16 X 1.25 Washer, Flat .375 Transmission Shaft Rod Transmission Shaft Knob Bell Housing Bell Housing Side Cover (Not Shown) Cover Plate, Bottom (Not Shown) Screw, HC 10mm X 1.50 X 25mm Washer, Lock 10mm Eng/Trans Support Spacer Enclosure, Clutch Relay Screw, PH 10-24 X .750 Bracket, Enclosure, Clutch Solenoid Clutch Sleeve Ant-Rotation Bracket Hydraulic Clutch - Model 211 Clutch Drive Shell Bell Housing Spacer Bearing Bearing Carrier Engine Vent Junction Box Screw, HC .250-20 X 1.00 Screw, HC .250-20 X .500 Washer, Lock .250 Mount Plate Screw, HC M10 X 30mm Washer, Lock 10mm V-Belt Solenoid Bracket, V-Belt Solenoid Screw, HC .250-20 X .750 Washer, Flat .25 Clutch Capture Spacer Screw, SFH .3125-18 x .750
3.4.4
POWERTRAIN ASSEMBLY McL 42 HD
3.4.5
GEARBOX DETAIL
POWERTRAIN ASSEMBLY McL 42 HD
ITEM # 1
11
QTY. 1 4 1 40 40 1 4 2 1 4 4 1 1 1 1 2 2 2 1 1 4 4 1
NUMBER 4800302 4800307 4800103 U001440 U210160 4800306 U030010 W200195 4800348 U001380 U210160 U420041 4810330 4810331 4810332 U010250 U010261 U100140 4810333 4800395 U210110 U070030 4810339
12
2 2 2
U200100 U120015 3600131
13 14
1 1
15 16
1 1
4801306 4801303 U024010 U022155 3600115
2
3 4 5
6 7 8
9 10
GEARBOX DETAIL
DESCRIPTION Ge arb o x Ge arb o x Se al Plate Ad ap te r Scre ws Ge arb o x Ad ap te r Ring Scre w, HC .750-10 x 2.00 (No t Sho wn) Washe r, Lo ck .750 (No t Sho wn) Ge arb o x Se al Plate Scre w, SFH .250-20 X .563 O-Ring Shaft, Inp ut Ad ap te r Scre w, HC .750-10 X 2.00 Washe r, Lo ck .750 Ke y Co up ling Flang e Ce nte r Me mb e r Co up ling Ad ap te r Scre w, HSH .500-13 X 3.75 Scre w, HSH .500-13 X 4.75 Nut, He x .500-13 Co mp anio n Flang e Drag Brake Disk Washe r, H-C .500 Scre w, CB, 12Pt. .500-13 X 3.25 Drag Brake Mo unt Asse mb ly Co ntains: 4810338 Brake Mo unt 4810336 Brake Mo unt Blo ck U000180 Scre w, HC 5/16-18 X 3/4 U210040 Washe r, Lo ck 5/16 Washe r, Flat .500 Nut, Nylo c.500-20 Bulkhe ad Ad ap te r Kit Co ntains: 1 Fie ld Hub 2 Nut, Jam Brake Band Brake Band Cab le Lo ck Scre w, Se t .250-20 X .500 KN Cup Scre w, Sho uld e r .375 x 1.00 Thro ttle Cab le
3.4.6
DOG PLATE ASSEMBLY McL 42 HD
3.5.1
DOG PLATE ASSEMBLY McL 42 HD
ITEM #
QTY.
1 2 3 4
1 2 2 2 2 2 4 2 2 2 4 4 4 3 1 2 1 1 8 8 4 4 1 1 1 2 2 2 2
5 6
7 8 9
10
NUMBER
DESCRIPTION
4210402 4210410 U600060 W000070 4800418 U001505 U200160 U100200 4800808 4800437 U000060 U100020 U200020 4800430 4801710 U001505 4810401 4800425 U000400 U210060 U000400 U200060 4800412 4800413 4800414 U000060 U210020 U200020 U120100
Dog Plate D og P i n Dog Pin Compression Spring Dog Plate Roller Roller Spacer Screw, HC .750-10 X 4.00 G8 Washer, Flat, Large .750 Nut, HC .750-10 Dog Plate Switch Switch Mount Screw, HC .250-20X1.00 Nut, Hex .250-20 Washer, Flat .250 Cylinder Pin Dog Pin Cylinder Screw, HC .750-10 X 4.00 Cylinder Cover Box Top Cover Screw, HC .375-16 X .750 Washer, Lock .375 Screw, HC .375-16 X .750 Washer, Flat .375 Outlet Box Outlet Cover Outlet Grommet Screw, HC .250-20 X 1.00 Washer, Lock .250 Washer, Flat .250 Nut, Lock .250-20
3.5.2
42” CASING PUSHER/SPOIL EJECTOR McL 42 HD
3.6.1
42” CASING PUSHER/SPOIL EJECTOR McL 42 HD
ITEM #
QTY.
NUMBER
DESCRIPTION
1
1 4 4 4 1 1 1 1 12 12 1 1
4210501 4810129 4810134 U001570 4800514 4800550 U320015 4800515 U001584 U210210 4210523 4210528
42" Casing Pusher Anchor Pins Heavy Duty Washer Screw, HC 1-8 X 5.00 G5 Spoil Door Hinge Rod Pin, Cotter 1/8 X 1.00" 4" Hex Chuck Screw, HC 1 1/8 - 12 X 3.50" Washer, Lock 1 1/8" 42" Paddle Assembly 42" Saddle
2
3
4 5
Optional Equipment (Available upon request)
6
7
A A740201108102 A 700200 A 421012 A 700240 A 421018 A 700300 A 421020 A 700360 A 421024 A 470020 A042201102300 U A 6 A7402012003S A 70024S A7402003000S 34 A A A7402003060S 35 A A7609004122S S U A020000808306 U A26190011080S U A16090012240S
A Addaapptteerr K Kiitt,, 1182"" Adapter Kit, 20" Adapter Kit, 16" Adapter Kit, 24" Adapter Kit, 18" Adapter Kit, 30" Adapter Kit, 20" Adapter Kit, 36" Adapter Kit, 24" Adapter Kit, 42" Acdraepwt,eS rK S Qit.,73500"-10 x 3.50 (3 Req'd) A d a p t e r K Shoe, 20" iAt,d3a6p"ter Shoe, 24" Adapter Shoe, 3102" Adapter S S Shhooee,, 316" Adapter S Shhooee,, 4128" Adapter S Schroeew,,2H0C " A.5d0a0p-t1e3r X 2.00 (4 Req'd) W a s h e r , L Shoe, 24"oAcdka.5p0te0r (4 Req'd) N 00d-a1p3te(r4 Req'd) Suhto, eH,e3x0."5A
A 69030S
Shoe, 36" Adapter
3.6.2
MASTER TRACK ASSEMBLY McL 42HD
3.7.1
MASTER TRACK ASSEMBLY McL 42HD
ITEM # 1 2 3 4 5 6
QTY. 3 1 1 40 40 40
NUMBER 4210601 4210609 4210614 U001420 U210160 U100200
DESCRIPTION Master Track Extension Track Push Plate Screw, HC .75-10 X 2.50 Washer, Lock .750 Nut, Hex .750-10
3.7.2
HYDRAULIC TANK ASSEMBLY McL 42HD
HYDRAULIC TANK ASSEMBLY McL 48/54
ITEM # 1 2 3 4 5 6 7
QTY. 1 2 1 1 1 1 2
NUMBER 4210702 4800758 4800759 T720060 4800761 4210711 T405060
DESCRIPTION Hydraulic Tank Clean Out Cover Kit Fill Assembly Kit Sight Gauge Kit Suction Strainer Return Filter Drain Plug
3.8.1
FUEL TANK ASSEMBLY McL 42HD
FUEL TANK ASSEMBLY McL 48/54
ITEM # 1 2 3
QTY. 1 1 1
NUMBER 4210220 4800278 8010006
DESCRIPTION Fuel Tank Lockable Fuel Cap Kit Sight Gauge, 6" Kit
3.9.1
HYDRAULIC SYSTEM
HOSES AND FITTINGS
McL 42 HD
4.1.1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
4.1.2 HOSE ROUTING BASE MANIFOLD -- BASE CYLINDER QUICK DISC MALE LEFT CYLINDER, BASE END -- BASE MANIFOLD P2 RIGHT CYLINDER, BASE END -- BASE MANIFOLD P3 ROD MANIFOLD -- ROD CYLINDER QUICK DISC FEMALE LEFT CYLINDER, ROD END -- ROD MANIFOLD P2 RIGHT CYLINDER, ROD END -- ROD MANIFOLD P3 TRACK BRAKE -- QUICK DISC DOG PLATE CYLINDER -- HOUSING COUPLING
1 2 3 4
#
T400545 T401635 T405120 T401710 T401586 T400392 T400546 T401700 T400028 T401065 T400803 T412008 T412010 T403060 T400024 T400815 4800776 4800775
PART NO.
TH42001 TH42002 TH42003 TH42004 TH42005 TH42006 TH42007 TH42008
PART NO.
CYLINDER MANIFOLD (QTY 2) THRUST CYLINDER (QTY 2) TRACK BRAKE CYLINDER DOG PLATE CYLINDER
HYDRAULIC COMPONENTS 4800731 4800729 4810750 4801710
PART NO.
McL 42 HD
1 2 3 4 5 6 7 8
UNION 16MB-16MF ELBOW 90 16MB-16MF PLUG 16MB ELBOW 90 20MB-16MF UNION 45 16FP-16FP BULKHEAD 45 16MJ-16MJ UNION 16MP-16MF SWIVEL 90 4MP-6MJ UNION 6MJ-6MP ELBOW, 90 6FP-6MP UNION 6MP-6MP QUICK DISC, MALE 6FP CAP QUICK DISC UNION 16MP-8FP UNION 8MP-6FP UNION 16FJ-16MP QUICK DISC FEMALE 16FP QUICK DISC MALE 16FP
FITTING DESCRIPTION
HYDRAULIC SYSTEM HOSES AND FITTINGS
See page 4.1.4 for fittings and components callout
HYDRAULIC SYSTEM McL 42 HD
CARRIAGE
4.1.3
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49
FITTING DESCRIPTION
ELBOW, 45 32MP-32MJ KIT #32 SPLIT FLANGE COMPLETE ELBOW, 90 10MB-12MJ ELBOW, 90 12MP-12MJ UNION, 12MP-6MJ UNION, 12MP-12MP UNION, 12MP-6MJ ELBOW, 90 6FJ-6MJ UNION, 24MB-24MJ ELBOW, 90 24FJ-24MJ TEE, 6FJ-6MJ-6MJ ELBOW, 90 6MB-6MJ UNION, 6MB-6MB QUICK DISC., FEMALE 6FP DUST CAP, QUICK DISC., 6FP UNION, 6MP-6MJ UNION, 6MB-6MJ UNION, 4MB-4MJ ADAPTER, SPLIT FLANGE 16FB UNION, 8MB-8MJ UNION, 16MB-16MF ELBOW, 90 6MB-8MJ ELBOW, 90 6MB-6MJ UNION, 6MB-6MB UNION, 8MB-10MJ UNION, 10FJ-6MJ UNION, 8MB-4MJ ELBOW, 90 10MB-8MJ UNION, 16MB-16MF UNION, 4MB-4MJ TEE, 4FJ-4MJ-4MJ UNION, 4FP-4MJ UNION, 16MB-16MF UNION, 16MF-16MP QUICK DISC., MALE 16FP QUICK DISC., FEMALE 16FP PLUG, 8MP O-RING #6 SAE ELBOW, 90 6FJ-6MJ UNION, 6FJ-6FP UNION, 6MP-6MP QUICK DISC., MALE 6FP UNION, 12MP-8FP
NOTE: For replacement Hose Assemblies,
please include hose length and end fittings. 4.1.4 T401228 T400083 T400803 T412008 T403085
T405062 W200015
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
15
14
12 13
8 9 10 11
7
1 2 3 4 5 6
PART NO. TH48120 TH48121 TH48122 TH48123 TH48124 TH48125 TH48126 TH48127 TH48128 TH48129 TH48130 TH48131 TH48132 TH48133 TH48134
HOSE ROUTING HYD. TANK — PUMP (INLET) CASE DRAIN — HYD. TANK MANIFOLD DRAIN — HYD. TANK 2ND FILTER PRV #3 — MANIFOLD TEE DRAIN PLUMBING MANIFOLD — CHECK VALVE MANIFOLD MANIFOLD, V1 — DOG PLATE CYLINDER MANIFOLD, V2 — TRACK BRAKE CYLINDER PUMP (OUTLET) — PRV #2 PUMP #X — SHUTTLE VALVE #2 CONTROL VALVE #T — HYD. TANK MAIN FILTER SHUTTLE VALVE #3 — CONTROL VALVE L.S. TEE PUMP (OUTLET) — CONTROL VALVE #P1 CONTROL VALVE L.S. TEE — PRESSURE GAUGE CONTROL VALVE #B — FITTING BULKHEAD ROD END CONTROL VALVE #A — FITTING BULKHEAD BASE END
T404010 T400027 T400710 T402148 T400391 T400035 T400039 T400033 T400290 T400705 T400036 T401290 T400160 T400142 PART NO. 4800723 T700080 4800769 4800778 4800784 4800765 4801720 4801700 4801703 2400367 4800785 4210715 4801701 4801702 4810712 3600345 3600346 3600347 2400368 2400367 T720012
UNION, 8MP-6FP UNION, 6MP-6MB UNION, 8FJ-6MB TEE, 6MB-6MJ-6MJ BULKHEAD, 6MJ-6MJ UNION, 10MB-6MJ UNION, 6FJ-4MJ UNION, 6MJ-5MB UNION, 24MJ-16MB UNION, 8FJ-6MJ UNION, 6MB-6FJ ELBOW,90 10MB-6MJ UNION, 10MB-8MJ UNION, 8FJ-6MP
PART NO.
HYDRAULIC COMPONENTS IN-TANK RETURN FILTER SECOND CIRCUIT RETURN FILTER HYDRAULIC PUMP CONTROL VALVE PRESSURE GAUGE PRESSURE REDUCING VALVE BODY CARTIDGE SHUTTLE VALVE BODY CARTIDGE PLUMBING MANIFOLD CHECK VALVE MANIFOLD, SECOND CIRCUIT SOLENOID VALVE (V1 & V2) CARTIDGE COIL CLUTCH PRESSURE REDUCING VALVE ASSEMBLY CLUTCH SOLENOID VALVE CARTIDGE BODY COIL FILTER SCREEN ASSEMBLY FILTER SCREEN CARTIDGE FILTER SCREEN BODY CLUTCH PRESSURE GAUGE (0-600 PSI)
50 51 52 53 54 55 56 57 58 59 60 61 62 63
FITTING DESCRIPTION
McL 42 HD
T400545 T400546 4800775 4800776
T400570 T402010 T400110
T400038 T412009 T412010 T400028 T400037 T400570 4800767 T400140 T400545 T401260 T401250 T400038 T400400 T403130 T400134 T401300 T400545
T401565 T410450 T401581 T401180 T400085 T400800 T400085 T401228 T400580 T401730 T402153 T401250
PART NO.
HYDRAULIC SYSTEM CARRIAGE
ELECTRICAL SYSTEM
WIRING DIAGRAM ENGINE DETAIL
McL 42 HD
4.2.1
ELECTRICAL SYSTEM
WIRING DIAGRAM JUNCTION BOX DETAIL
McL 42 HD
4.2.2
WIRING DIAGRAM
CONTROL BOX
HYDRAULIC CLUTCH SOLENOID (NO POLARITY)
McL 42 HD
4.2.3
WIRING DIAGRAM
INSTRUMENT PANEL
McL 42 HD
4.2.4
COMPONENT WIRING
WIRING DIAGRAM McL 42 HD
4.2.5
5.2 -5.8 MACHINE COMPONENTS McL 42 HD
DETAIL
PAGE
GEARBOX TRANSMISSION PARTS HYDRAULIC PUMP COUPLING HYDRAULIC CLUTCH HYDRAULIC THRUST CYLINDER HYDRAULIC DOG PLATE CYLINDER HYDRAULIC VALVE
5.2.1-5.2.3 5.3.1-5.3.14 5.4.1 5.5.1 5.6.1 5.7.1 5.8.1
5.2.0
GEARBOX COMPONENTS McL 42 HD
5.2.1
GEARBOX COMPONENTS McL 42 HD
IT E M # 1A 1K 1I 1G 1C 1D 1E 1F 1B 1L 1N 5 24 1M 17 18 1U 3C 3B 3E 3A 3F 1J 1H 4 3G 3D 3H 16 15 26 13 25 1V 1T 7 1P 22 6 8 6
QT Y. 1 1 4 1 1 1 1 1 1 1 8 2 1 8 16 4 1 6 3 3 1 1 1 1 1 3 6 3 2 4 1 1 2 2 1 2 3 20 1 1 1
N U MB E R 480030201 480030202 480030203 480030204 480030205 480030206 480030207 480030208 480030209 480030210 480030211 480030212 480030213 480030214 480030215 480030216 480030217 480030218 480030219 480030220 480030221 480030222 480030223 480030224 480030225 480030226 480030227 480030228 480030229 480030230 480030231 480030232 480030233 480030234 480030235 480030236 480030237 480030238 480030239 480030240 480030241
MODEL# SERIAL #
D E S C R IP T ION Spindle Carrier, Bearing Plate, Rectangular Housing Bearing, Tapered Bearing, Tapered Bearing, Tapered Bearing, Tapered Seal, Face Shim, Steel Bolt, Hex-Special O-Ring Plate, ID Bolt, Hex-UNC Bolt, Hex-UNC Bolt, Shoulder Seal, Boot Bearing, Cup Pin, Roll Shaft, Planet Carrier Gear, Cluster Set Gear, Internal Coupling, Internal Gear, Ring Spacer, Thrust Bearing, Tapered Ret, Ring-Extension Bearing, Thrust Washer, Thrust Spacer, Input Gear, Sun Screw, Drive Pipe Plug, STD-NPT Pipe Plug, STD-NPT Pipe Plug, MAGN-NP Pipe Plug, MAGN-NP Washer, Lock Plug, Cardboard Washer, Thrust Cover, Input
Note: McLaughlin Manufacturing Co. is not authorized to service Gearboxes. Consult McLaughlin Manufacturing Co. for repair manual or the name of an authorized service dealer near you.
5.2.2
GEARBOX MAINTENANCE SCHEDULE McL 42 HD
DATE/HRS
SERVICE PERFORMED
5.2.3
BY
TRANSMISSION COMPONENTS McL 42 HD
MODEL# SERIAL #
Note: McLaughlin Manufacturing Co. is not authorized to service transmissions. Consult an authorized dealer of the transmission manufacturer for parts and /or service. Transmission model and serial number is required for part orders. Contact McLaughlin Manufacturing Co. for a distributer near you.
5.3.1
TRANSMISSION DETAIL McL 42 HD
SHIFT BAR HOUSING
5.3.2
TRANSMISSION DETAIL McL 42 HD
5.3.3
TRANSMISSION DETAIL McL 42 HD
LEVER ASSEMBLY
5.3.4
TRANSMISSION DETAIL McL 42 HD
5.3.5
TRANSMISSION DETAIL McL 42 HD
TRANSMISSION CASE
5.3.6
TRANSMISSION DETAIL McL 42 HD
5.3.7
TRANSMISSION DETAIL McL 42 HD
TRANSMISSION CASE
5.3.8
TRANSMISSION DETAIL McL 42 HD
5.3.9
TRANSMISSION DETAIL McL 42 HD
TRANSMISSION CASE
5.3.10
TRANSMISSION DETAIL McL 42 HD
5.3.11
TRANSMISSION DETAIL McL 42 HD
INPUT SHAFT
5.3.12
TRANSMISSION DETAIL McL 42 HD
5.3.13
TRANSMISSION MAINTENANCE SCHEDULE McL 42 HD
DATE/HRS
SERVICE PERFORMED
5.3.14
BY
HYDRAULIC PUMP COUPLING McL 42 HD
HYDRAULIC PUMP COUPLING McL 42 HD
ITEM # 1
2 3 4
QTY. 1 1 1 1 1 4 1 8
NUMBER 4800355 4800356 U010220 4800357 4800358 U010085 4210308 U030900
DESCRIPTION Coupling Hub Snap Ring Screw, HSH .438-14X1.50" Nylon Sleeve Pully Hub Screw, HSH .375-16X1.25" Pully Flange Screw, Soc 8mm X 30mm
5.4.1
HYDRAULIC CLUTCH ASSEMBLY McL 42 HD
HYDRAULIC CLUTCH ASSEMBLY ITEM# 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
QTY 1 1 1 1 1 1 1 1 6 6 2 6 1 3 1 1 3 1 2 1 1
NUMBER 481039901 481039902 481039903 481039904 481039905 481039906 481039907 481039908 481039909 481039910 481039911 481039912 481039913 481039914 481039915 481039916 481039917 481039918 481039919 481039920 481039921
5.5.1
DESCRIPTION RETAINING RING ANGULAR CONTACT BEARING (7215) ANGULAR CONTACT BEARING (7217) CYLINDER ASSEMBLY PISTON SPACER BEARING HUB SEPARATOR PLATE HIGH COLLAR LOCK WASHER 5/16-18 UNC X 0.75 LG SHCS FRICTION DISC COMPRESSION SPRING SPACER 1/4-20 UNC X 0.50 LG FHSCS O-RING O-RING 5/16-18 UNC X 0.625 LG FHSCS PRESSURE PLATE #10-24 X 0.75 LG SHCS HUB BACKPLATE
HYDRAULIC THRUST CYLINDER McL 42 HD
HYDRAULIC CYLINDER McL 42 HD
ITEM # 1 2 3 4 5 6
QTY. 1 1 1 1 1 1
NUMBER 480072901 480072902 480072903 480072904 480072905 480072906
DESCRIPTION Tube Assembly Rod Assembly Piston Rod Gland Assembly Lock Nut S eal K i t
Complete Seal Kit to include: IT E M # A B C D E
QT Y. 1 1 1 1 1
D E S C R IP T ION Piston Seal Rod Seal Wiper O-Ring O-Ring & Back Up
5.6.1
COMPONENTS
HYDRAULIC THRUST CYLINDER McL 42 HD
5.6.2
SEAL DETAILS
HYDRAULIC DOG PLATE CYLINDER McL 42 HD
ITEM# 1 2 3 4
QTY 1 1 1 1
NUMBER 4801710-05 4801710-15 4801710-10 4801710-20
DESCRIPTION Threaded Cap Rod/Clevis Weldment Barrel/Clevis Weldment Seal Kit
HYDRAULIC DOG PLATE CYLINDER
SEAL KIT ASSEMBLY
McL 48/54
New Seal Kit Reference Print
O-RING #218
O-RING #014
O-RING #131
5.7.1
O-RING #210
WIPER
HYDRAULIC VALVE PARTS McL 42 HD
VALVE HANDLE - MAIN THRUST VALVE McL 48/54
ITEM # 1 2 3
QTY. 1 1 1
NUMBER 4800810 3610713 4800854
DESCRIPTION Grip with Switch Valve Lever Adapter Switch Adapter
5.8.1
HYDRAULIC CLUTCH McL 42 HD
6.1 OPERATING NOTE: 1. Engaging the clutch against an immovable load, will cause premature failure of the clutch. Do not cycle the clutch (on/off/on/off etc.) with augers under-load. COLD WEATHER OPERATION Cold weather affects the operation of the boring machine. Cold hydraulic fluid causes sluggish machine performance and can contribute to the premature failure of some machine components. Before starting to bore, the machine and hydraulic fluid must be at operating temperature (i.e. the machine must be warmedup before boring). Warm-up procedure: 1. Start the machine and let it run at idle for 1-2 minutes. 2. Slowly increase the engine rpm to about 1/2 to 3/4 full throttle 3. Allow the engine to run at this higher speed for 4-5 minutes 4. Extend and retract the thrust cylinders to warm up the hydraulic fluid. 5. Occasionally running the machine over relief will help to reduce the warm-up time. Only after the machine is warmed up should you begin to bore! Hydraulic Clutch Operation: SLUGGISH OR DELAYED APPLY TIME FOR THE CLUTCH CAN CAUSE PREMATURE FAILURE. The apply time for the clutch (the time it takes to build full pressure) is critical to the operation of the machine. Normal clutch apply time is less than 2 seconds. If the apply time is greater than 2 seconds, wait until the oil temperature increases before boring. The apply time can be monitored by the pressure gauge on the console panel. Cycle the clutch during warm-up, waiting 10 seconds between engagements. WHEN APPLYING THE CLUTCH DURING THE WARM-UP PERIOD, THE TRANSMISSION MUST BE IN NEUTRAL. Do not cycle the clutch during warm-up while coupled to loaded augers. Boring with an extended clutch apply time will cause premature failure of the clutch. The hydraulic clutch operating system has 2 switches. 1. O.P.C. Switch 2. Clutch Switch Both the O.P.C. switch and the Clutch switch must be in the “ON” position before the clutch will operate. If the clutch does not operate, make sure that both of these switchs are “ON”. The hydraulic pressure is set at the factory for 225 psi. This pressure must be maintained for proper operation. DO NOT operate the clutch if the clutch pressure gauge is reading below 150 psi. Too low an operating pressure will result in premature clutch failure.
6.1.1
HYDRAULIC CLUTCH McL 42 HD
COLD WEATHER OPERATION Hydraulic Fluid: Use the alternate hydraulic fluid for the following: - To reduce warm-up time before boring. - When consistently boring in cold weather. Standard hydraulic fluid: - ISO grade #46 with anti-wear additives. - 76 Unax AW #46 - Or equivalent Alternate hydraulic fluid: - ISO grade #32 Wide Temperature Range oil with anti-wear additives. - 76 Unax AW-WR #32 - Or equivalent Consult McLaughlin for more information.
6.1.2
HYDRAULIC CLUTCH McL 42 HD
6.2 TROUBLESHOOTING DANGER: DO NOT OPERATE MACHINE IF CLUTCH IS NOT OPERATING PROPERLY. DEATH OR SERIOUS INJURY WILL RESULT. The hydraulic clutch supplied with this machine is a dry-running, self-adjusting, twin-disk clutch. The clutch requires very little maintenance. Following is a list of symptoms which may require servicing the clutch. 1. Contamination The clutch is designed to run in a dry environment. However, the clutch housing can become contaminated. Contamination can result from dirt or sandy grit, oils, or water (which causes rust) entering the clutch housing. Clean the disc pack kit with kerosene to restore to normal condition. 2. Drag in Neutral It is natural for a twin-disc clutch to have a small amount of drag in the disengaged state. The drag should be more noticeable at low engine speeds and in low transmission gears. A. New machines or rebuilt clutches There is an indeterminate break-in time required for new clutches. Once a clutch has been working for a while, it should seat itself and neutral drag should be at a minimum. B. Abrupt changes in clutch drag If the drag in the clutch abruptly increases, it may be due to insufficient spring tension between the clutch discs. Weaker springs cause more drag between the discs of the clutch. Excessive heat, generated in the clutch by cycling the clutch or by applying the clutch against locked augers, will weaken the springs and cause excessive nuetral drag. Replace disc pack kit and inspect all other components for damage and replace as necessary. Refer to the Clutch Components and Disassembly/Assembly section of this manual for components and proper clutch service procedures.
6.2.1
5.1 ENGINE DETAILS McL 42 HD
DETAIL
PAGE
ENGINE DESCRIPTION MODEL DESIGNATION ENGINE PARTS LUBE OIL CIRCUIT FUEL SYSTEM SCHEMATIC ENGINE COOLING COMMISSIONING STARTING MONITORING SYSTEMS STOPPNG OPERATING CONDITIONS LUBE OIL OPERATING MEDIA MAINTENANCE SCHEDULE LUBRICATION SYSTEM FUEL SYSTEM COOLING SYSTEM CUMBUSTION AIR FILTER BELT DRIVES ADJUSTMENTS ACCESSORIES/BATTERY ENGINE CLEANING ADDITIONAL MAINTENANCE DIAGNOSIS CHART ENGINE PRESERVATION ENGINE SPECIFICATIONS AND SETTINGS TORQUE WRENCH SETTINGS/TOOLS ORDERING SPARE PARTS
5.1.1 5.1.2-5.1.3 5.1.4-5.1.5 5.1.6 5.1.7 5.1.8 5.1.9-5.1.10 5.1.11 5.1.12 5.1.13 5.1.14 5.1.15 5.1.16 5.1.17-5.1.18 5.1.19-5.1.20 5.1.21 5.1.22 5.1.23-5.1.24 5.1.25-5.1.26 5.1.27 5.1.28-5.1.29 5.1.30 5.1.31 5.1.32 5.1.33 5.1.34-5.1.35 5.1.36 5.1.37
5.1.0
ENGINE DESCRIPTION GENERAL 1
DEUTZ Diesel Engines
Service and Maintenance
DEUTZ Service
are the product of research and development ranging over many years. The know-how thereby gained, coupled with high demands with regard to quality, forms the guarantee for the manufacture of engines featuring long service-life, high reliability, and low fuel consumption. It goes without saying that the high demands regarding protection of the environment are also fulfilled.
will also play a decisive role as to whether the engine fulfills to your satisfaction the demands you make on it. Observance of the prescribed maintenance intervals and careful carrying out of the service and maintenance jobs are therefore essential. Particular attention must be given with regard to applications involving differing and harder operating conditions as compared with normal operation.
In case of operational troubles and queries concerning spare parts, please contact your DEUTZ agent. Where necessary, our trained specialists will ensure a quick and professional repair, using DEUTZ spare parts. Genuine DEUTZ spare parts are always manufactured to the latest technical standards. More information on DEUTZ SERVICE can be found at the end of this Operation Manual.
Beware of Running Engine
Safety
Shut the engine down before carrying out maintenance or repair work. Ensure that the engine cannot be accidentally started - accidents may otherwise occur. When the work is complete, be sure to refit any panels and guards that have been removed. Never fill the fuel tanks while the engine is running. Observe industrial safety regulations when running the engine in an enclosed space or underground.
When reading through this Manual, you will find this symbol marking all safety instructions and proceed with special care. Pass on these safety instructions to your operating personnel. In addition, it is also necessary to observe the official safety and accident prevention rules.
5.1.1
The seals and gaskets used in this engine are asbestos-free. When carrying out maintenance and repair work, please use appropriate spare parts.
MODEL DESIGNATION 2.1 Model
2.1.1 Rating Plate The model designation A, the engine serial number B and the performance data are stamped on the rating plate. The model and engine serial number must be given when ordering parts.
2.1.2 Location of Rating Plate The rating plate C is attached to the crankcase; depending on the design, a second rating plate may be attached to the air duct.
2.1.3 Engine Serial Number The engine serial number D is stamped onto the crankcase as well as on the rating plate.
2.1.4 Numbering of Cylinders The cylinders are numbered consecutively, beginning at the flywheel end.
Adjustments to the regulator are to be carried out only by authorized DEUTZ SERVICE - specialists.
5.1.2
ENGINE DESCRIPTION 2.1 Model
2.1.5 Direct Injection FL 912 Engines with direct injection are used where high performance is required.
2.1.6 Two-stage Combustion FL 912W Engines with two-stage combustion are used where it is particularly important to keep exhaust emissions to an absolute minimum.
5.1.3
ENGINE DESCRIPTION
2.2 Engine Illustrations
2.2.1 Service Side F4L 912 1 Fan 2 V-belt (fan) 3 Injection pump 4 V-belt (alternator) 5 V-belt pully 6 Tension roller 7 Oil fill point 8 Oil pan 9 Oil drain plug 10 Fuel pump 11 Oil dipstick 12 Lube oil filter 13 Easy-change fuel filter 14 Air duct cover 15 Cylinder-head cover
2.2.2 Exhaust Side F4L 912 16 17 18 19 20 21 22 23
5.1.4
Air intake pipe Exhaust manifold pipe Screen Alternator Starter Engine mounting Crankcase Crankcase ventilation
ENGINE DESCRIPTION
2.2 Engine Illustrations
2.2.3 Service Side BF4L 913 1 Fan 2 V-belt (fan) 3 V-belt (alternator) 4 V-belt pully on crankshaft 5 Tension roller 6 Oil fill point 7 Oil drain plug 8 Fuel filter cartridge 9 Fuel pump with fuel precleaner 10 Injection pump 11 Oil dipstick 12 Lube oil filter cartridge 13 Air duct cover 14 Engine oil radiator cover
2.2.4 Exhaust Side BF4L 913 15 16 17 18 19 20 21 22
Exhaust manifold line Terminal housing Starter Crankcase ventilation Oil pan Alternator Exhaust turbocharger Air-intake pipe-exhaust turbocharger 23 Charge-air line
5.1.5
ENGINE DESCRIPTION 2.3 Lube Oil Circuit
2.3.1 Lube Oil Circuit FL 912/913 1 Oil Pan 2 Intake Manifold 3 Oil pump 4 Oil pressure control valve 5 Pressure-oil line 6 Bypass line or selectively 7 Finned pipe spiral or selectively 8 Frame oil cooler 9 Lube oil filter 10 Safety valve 11 Main oil gallery 12 Crankshaft bearing 13 Con-rod bearing 14 Camshaft bearing 15 Tappets 16 Push rod (hollow, for oil feed to rocker arm lubrication) 17 Rocker arm bearing 18 Metering plug (r arm lubrication)* 19 Protective sleeve for push rod 20 Throttle bore (for lubrication of the gear wheels) 21 Injection jet for cooling the pistons 22 Connection for oil pressure gauge 23 Oil pressure gauge 24 Injection pump connected to lube oil circuit 25 Connection point for oil heating**
1 Oil Pan 2 Intake manifold 3 Oil pump 4 Oil pressure control valve 5 Pressure-oil line 6 Connecting line to oil cooler 7 Frame oil cooler 8 Lube oil filter 9 Safety valve 10 Main oil gallery 11 Crankshaft bearing 12 Con-rod bearing 13 Camshaft bearing 14 Tappets (with impulse lubrication of the rocker arm) 15 Push rod (hollow, for oil feed to r. arm lubrication) 16 Rocker arm bearing 17 Metering plug (r arm lubrication)* 18 Protective sleeve for push rod (oil return form cylinder head to crankcase) 19 Throttle bore (for lubrication of the gear wheels) 20 Injection jet for cooling the pistons 21 Oil line for lub. of the exhaust turbocharger 22 Oil ret. line from exhaust turboc. to the crankcase 23 Oil pressure gauge 24 Partial flow lube oil filter 25 Connection point for oil heating** 26 Injection pump connected to lube oil circuit
2.3.2 Lube Oil Circuit BF6L 913
5.1.6
* only for inclined engines ** in this instance the filter holder must be replaced. Please contact our service representative for this alteration.
ENGINE DESCRIPTION
2.4 Fuel System Schematic
2.4.1 Fuel Circuit 1 2 3 4 5 6 7 8 9 10 11
5.1.7
Fuel Tank Fuel line from tank to fuel pump Fuel supply pump Easy-change fuel filter Injection pump Injection lines Injection valves Oil leakage line Fuel overflow valve Overflow valve Fuel return line to tank A Clearance: keep as far apart as possible.
ENGINE OPERATION 2.5 Engine Cooling
2.5.1 Regulation of Coolant Flow using the Exhaust Thermostat 1 Pressure-oil line from engine to exhaust thermostat 2 Air line to exhaust thermostat 3 Exhaust manifold pipe 4 Exhaust thermostat 5 Control line to hydraulic coupling 6 Hydraulic coupling 7 Cooling fan 8 Cooling fan drive 9 Oil return line to crankcase 10 Ventilation line 11 Adjusting pin with special seal
2.5.2 Regulation of Coolant Flow using the Exhaust Thermostat and Solenoid 1 Pressure-oil line from engine to exhaust therostat 2 Air line to exhaust thermostat 3 Exhaust manifold pipe 4 Exhaust thermostat 5 Control line to hydraulic coupling 6 Hydraulic coupling 7 Cooling fan 8 Cooling fan drive 9 Oil return line to crankcase 10 Ventilation line 11 Adjusting pin with special gasket 12 Solenoid
5.1.8
ENGINE OPERATION
3.1 Commissioning
3.1.1 Adding Engine Oil
3.1.2 Filling Oil Bath Air Cleaner
3.1.3 Adding Fuel
As a rule, engines are delivered empty of oil. Pour lube oil into the oil filler neck (arrow). For oil grade and viscosity, see pg 4.1
Fill oil cup 1 of the oil bath air cleaner with engine oil up to the arrow. For oil grade and viscosity, see 4.1
Use only commercial-grade diesel fuel. For fuel grade see 4.2. Use summer or winter-grade fuel, depending on the ambient temperature.
Oil may not be filled into the dust collector of the precleaner, if this is fitted.
3.1.4 Ventilation Model: “Bosch” fuel pump
Never fill the tank while the engine is running. Keep the filler cap area clean and do not spill fuel.
3.1.4 Ventilation Model: “IMSA” fuel pump
Loosen overflow valve 1 at the lower (larger) hexagon. Loosen hand pump 2 at the notched grip 3 by unscrewing by several turns to the left. Actuate hand pump 2 until bubble-free fuel is emitted at the loosened overflow valve 1. Tighten overflow valve1, continuing to pump at the same time. Tighten grip 3.
Loosen overflow valve 1 at the lower (larger) hexagon. Actuate preliminary pump lever 2 against the spring pressure until bubble-free fuel is emitted at the loosened overflow valve 1. Tighten overflow valve 1, continuing to pump at the same time.
5.1.9
ENGINE OPERATION
3.1 Commissioning
3.1.5 Other Preparations Check battery and cable connections see 6.7.1 Transport hooks Remove if fitted (see 6.7.3)
3.1.6 Additional Maintenance Work The following maintenance should be carried out after 50-150 operating hours: Change lube oil, see 6.1.2
Trial run After the engine has been prepared, let it run for about 10 minutes without load.
Change oil filter cartridge, see 6.1.3 Change fuel filter cartridge, see 6.2.1
During and after trial run - Check the engine for leaks.
Check V-belts and retension as necessary, see 6.5
After the engine has been turned off - Check the oil level, see 6.1.2 If necessary, top oil, see 3.1.1 Retension V-belts, see 6.5
Check valve clearance and adjust as necessary, see 6.6.1 Check the engine for leaks.
Breaking in During the break-in phase - about 200 operating hours - check the oil level twice a day. After the engine is broken in, checking once a day will be sufficient.
Check the engine mount and adjust as necessary, see 9.2
3.1.7 Selector Switch for Oil Heater
Position of selector switch for oil filter console with oil heater connection: Pos. 1: open Pos. 2: closed For engines without oil heating, the selector switch is always open Pos. 2: to lock closed.
5.1.10
ENGINE OPERATION 3.2 Starting
Starting without Cold-Start Aid
3.2.1 Electric Starting Before starting, make sure that nobody is standing in the immediate vicinity of the engine or driven machine. After repair work: Check that all guards have been replaced and that all tools have been removed from the engine. When starting with flame glow system, do not use any other starter substance (e.g. injection with start pilot). Caution: If the speed regulator has been removed, the engine must not be tested under any circumstances: Disconnect the battery. Do not actuate the starter for more than 20 seconds. If the engine does not catch wait a minute then try again. If the engine does not catch after two attempts, refer to the Diagnosis Chart (see 7.1)
with Cold-Start Aid/Flame Glow fr 60=9.5 and 19 volts
Insert key. - Position 0 = no operating voltage Turn key clockwise. - Position 1 = operating voltage - Pilot lights come on. Push the key in and turn further clockwise against spring pressure - Glow plug indicator light comes on - Position 2 = Preheat for approx. 60 seconds (hold key in position)* - Glow plug indicator light goes out - Position 3 = start Release key as soon as engine fires. - Pilot lights go out. * By afterignition in position 2 for up to approx. 3 mins, it is possible to lower further the exhaust gas opacity in the revving-up phase.
Where possible, disengage the clutch to separate the engine from any driven parts. Move speed control lever 1 into idle position.
with Cold-Start/Flame Glow Plug FR 20/30 = 11 and 23 volts
Insert key. - Position 0 = no operating voltage Turn key clockwise - Position 1 = operating voltage - Pilot lights comes on. Push the key in and turn further clockwise against spring pressure - Glow plug indicator light comes on - Position 2 = Preheat for approx. 20-30 seconds (hold key in position)* - Glow plug indicator light goes out - Position 3 = start Release key as soon as engine fires. - Pilot lights go out. * By afterignition in position 2 for up to approx. 3 mins, it is possible to lower further the exhaust gas opacity in the revving-up phase.
5.1.11
Insert key. - Position 0 = no operating voltage Turn key clockwise - Position 1 = no operating voltage - Pilot lights come on. Push the key in and turn it further clockwise against spring pressure - Position 2 = no function - Position 3 = start
with heating pipe
Insert key. - Position 0 = no operating voltage Turn key clockwise - Position 1 = operating voltage - Pilot lights comes on. Push key in and turn further clockwise against spring pressure. - Position 2 = Preheat for approx. 60 seconds (hold key in position)* - Position 3 = Start Release key as soon as engine fires. - Pilot lights go out.
* By afterignition in position 2 for up to approx. 3 mins, it is possible to lower further the exhaust gas opacity in the revving-up phase.
ENGINE OPERATION
3.3 Monitering Systems
3.3.1 Engine Oil Pressure
Oil Pressure Pilot Light The oil pressure pilot light comes on with operating voltage on and engine off.
Oil Pressure Indicator The pointer must remain in the green sector over the entire range.
Oil Pressure Gauge The pointer must indicate the minimum oil pressure (see 9.1).
The oil pressure pilot light should go out when the engine is running.
3.3.2 Engine Temperature
3.3.3 Cooling Fan Drive
Temperature Gauge The engine temperature gauge pointer should remain in the green sector most of the time. It should rarely enter the yellow-green sector. If the pointer enters the orange sector, the engine is overheating. Turn off and establish the cause from the Diagnosis Chart (see 7.1).
If the V-belt rips, pressure pin 1 of the electrical switch is actuated by the tension roller and an acoustic or light signal is given. Switch off the engine immediately to prevent overheating.
5.1.12
ENGINE OPERATION 3.4 Stopping
3.4.1 Mechanical Shutdown
Move speed control lever to low idle. Operate shutdown lever 2 until the engine comes to a stop. The charge pilot light and the oil pressure pilot light will come on when the engine stops. Turn key counter-clockwise (to position 0) and remove. The pilot lights will go out.
3.4.2 Electrical Shutdown
Turn key counter-clockwise (to position 0) and remove. The pilot lights will go out.
Ignition Key
5.1.13
ENGINE OPERATION
3.5 Operating Conditions
3.5.1 Winter Operation Lube Oil Viscosity - Select the oil viscosity (SAE grade) according to the ambient temperature when the engine is started, see 4.1.2 - Increase oil change frequency when operating below -10°C, see 6.1.1 Diesel Fuel - Use winter-grade diesel fuel for operation below 0°C, see 4.2.2 Additional Maintenance Work - Drain the sludge from the fuel tank once a week. (Unscrew the sludge drain plug). - If necessary, allow the oil in the oil bath air cleaner and the engine oil to settle at the ambient temperature. - Below -20°C, after removing the starter if necessary, smear the ring gear on the fly wheel via the pinion bore from time or time with cold-resistant grease, (e.g. Bosch grease FT 1 V 31). Cold-Start Aid - At temperatures near or below freezing point, use glow plugs if necessary, see 3.2.1. This not only lowers the starting limit temperature, but provides easier starting at temperatures normally not requiring a starting aid. Battery - Efficient cold starting requires a healthy battery, see 6.7.1 - The starting limit temperatures can be lowered by 4-5 °C by heating the battery up to about +20°C. (To do so, remove the battery and store in a warm place.)
3.5.2 High Ambient Temperatures High Altitude As the altitude and ambient temperature rise, the density of air tends to decrease, which affects the maximum power output of the engine, the exhaust gas quality and, in extreme cases, the starting behavior. Under transient conditions, the engine can be used at altitudes up to 1000m and temperatures up to 30°C. If the engine is to operate under more severe conditions (at higher altitudes or temperatures), it will be necessary to reduce the injected fuel quality and thus, engine power. If you have any doubts about engine operation under these or similar conditions, ask your engine or equipment supplier whether the engine has been derated in the interests of reliability, service life and exhaust gas quality (smoke). Otherwise contact DEUTZ SERVICE.
5.1.14
OPERATING MEDIA 4.1 Lube Oil
4.1.1 Quality Grade Lube oils are differentiated according to their performance and quality class. In commom use are specifications named after the API (American Petroleum Institute) and ACEA (European Engine OIl Sequences). Approved API Oils: At least:
CF-4
Approved ACEA Oils: At least
E1-96
4.1.2 Viscosity As the viscosity of the lube oil is dependent on temperature, the choice of SAE grade should be governed by the ambient temperature prevailing at the engine operating site. Optimum operating behaviour will be attained if you take the accompanying oil viscosity diagram as a guide. Should the temperature fall temporarily below the limits of SAE grade selected, cold starting may be affected but the engine will not be damaged. In order to keep wear to a minimum, do not exceed application limits for extended periods of time. Oil changes dictated by the seasons can be avoided by using multi-grade lube oils. Multi-grade oils particularly light flowing oils - also reduce fuel consumption.
Oil change intervals, see 6.1.1 Oil capacities, see 9.1
5.1.15
OPERATING MEDIA 4.2 Fuel
4.2.1 Quality Grade Use commercially available diesel fuel with less than 0.5% sulphur content. If the sulphur content is higher than 0.5% oil change intervals should be reduced, see 6.1.1 The following fuel specifications / standards are approved: DIN EN 590 BS 2869: A1 and A2 (with A2, take note of the sulphur content!) ASTM D 975-88; 1-D and 2-D NATO Code F-54 and F-75 Any exhaust emission levels, which may have been determined during type approval tests always refer to the reference fuel prescribed by the authorities for the type approval test.
4.2.2 Winter-Grade Fuel Waxing may occure at low temperatures, clogging the fuel system and reducing engine efficiency. If the ambient temperature is less than 0°C, winter-grade fuel (suitable down to -15°C) should be used. (This fuel is usually available from the filling stations well in advance of the cold months). Diesel fuel containing additives (Super diesel) is often on sale as well, for use down to -20°C. Below -20°C, petroleum must be added. For the required mixing ratios please refer to the adjacent diagram. For artic climate zones down to -44°C special diesel fuels can be used. If summer-grade diesel fuel must be used at temperatures below 0°C, up to 60% kerosene can be added (see diagram). In most cases, adequate resistance to cold can be obtained by adding a flow improver (additive). Please inquire at DEUTZ-PARTNER. Mix in tank only. Fill with the appropriate amount of kerosene first, then add the diesel fuel.
5.1.16
ROUTINE MAINTENANCE
5.1 Maintenance Schedule
5.2 Maintenance Charts The maintenance charts shown here are supplied as self-adhesive labels with each engine. They should be affixed where they can be seen clearly on the engine or driven equipment. Check that this is the case. If necessary, ask your engine or equipment supplier for a fresh supply of labels. Routine work should be carried out according to the schedule in 5.1
Stop the engine before carrying out any maintenance work.
5.1.17
ROUTINE MAINTENANCE
5.3 Completed Maintenance Jobs
5.1.18
SERVICE AND MAINTENANCE 6.1 Lubrication System
6.1.1 Oil Change Intervals The oil change intervals are dependent on the engine application and the quality of the lube oil. If the engine runs fewer hours during the year than stated in the table, the oil should be changed at least once a year. The table refers to the following conditions: - For diesel fuel: sulphur content max. 0.5% by weight. - Continuous ambient temperatures down to -10°C (+14°F) If the sulphur content is > 0.5 to 1% or the continuous ambient temperature below -10°C (+14°F), the intervals between oil changes should be halved. In case of fuels containing more than 1% sulphur, contact your service representative. Change the oil with the engine off but still warm (lube oil temperature approx. 80°C)
6.1.2
Checking Oil/ Checking Engine Oil 6.1.2.1 Checking Oil Level 6.1.2.2 Engine Oil Change
Ensure that the engine or vehicle is in a horizontal position. - Warm Engine: Switch off engine, wait 5 minutes and check the oil level. - Cold Engine: Check oil level. To this end: Remove the oil dipstick.
Ensure that the engine or vehicle is on a level surface. Allow the engine to warm up - Lube oil temperature approx. 80°C. Switch off the engine.
Wipe the dipstick with a non-fibrous, clean cloth. Insert it to the top and remove again. Check the oil level, and if necessary, top up to the “MAX” mark. - If the oil level is only just above the “MIN” mark, more oil must be added. The oil level must not fall below the “MIN” marking.
Place oil tray under the engine. Unscrew drain plug. Drain oil. Fit oil drain plug, with the new gasket and tighten firmly (for torque, see 9.2) Fill with lube oil. - For grade/viscosity, see 4.1 - For quantity, see 9.1 Check oil level, see 6.1.2.1 Be careful when draining hot oil danger of scalds! Do not let used oil run into the soil but catch it in a container ready for proper disposal.
5.1.19
SERVICE AND MAINTENANCE 6.1 Lubrication System
6.1.3 Changing Oil Filter
Undo the filter cartridge using a commercial tool and spin off. Catch any dripping oil.
Beware of burns from hot oil.
Clean any dirt from the filter carrier rim. Lightly oil the rubber gasket of the new oil filter cartridge. Screw in the new cartridge finger tight against the gasket.
6.1.4 Changing the Partail - Flow Oil Filter Insert
Unscrew oil drain plug 1 and drain off oil. Unscrew tension screw 2. Remove the cover. Unscrew the dirtied filter insert 3. Clean the filter housing. Check and if necessary replace cover seal 4. Screw in oil drain plug 1 with new seal 5. Fit new filter insert. Screw on cover and sealing ring 6. Check for leaks and check the oil pressure during a test run.
5.1.20
Tighten the oil filter cartridge with another half-turn. Check oil level, see 6.1.2 Check oil pressure, see 3.3.1 Check cartridge seal for leaks.
SERVICE AND MAINTENANCE 6.2 Fuel System
6.2.1 Changing Fuel Filter
Close fuel stopcock. Undo fuel filter cartridge with commercial tool and spin off. Catch any fuel.
No naked flames when working on the fuel system. NO SMOKING!
6.2.2 Fuel Precleaner Cleaning the Fuel “Bosch” model
Close the fuel shut-off valve. Loosen tensioning nut 2. Swing wire cup 1 to the side. Remove filter cone 5 with strainer 4 and clean in fuel. Use a new seal 3 for filter cone 5. Bleed the fuel system, see 3.1.4
Clean any dirt from the filter cartridge with a final half-turn. Apply light film of oil or diesel fuel to the rubber gasket of the new fuel filter cartridge.
Check for leaks.
Screw in the new cartridge finger tight against the gasket.
Cleaning the Fuel Filter “IMSA” model
Close the fuel shut-off valve. Loosen hexagonal nut 1 and unscrew with sealing ring 2. Remove cover 3. Remove fuel strainer 4.
Check for leaks. No naked flames when working on the fuel system. NO SMOKING!
Tighten the fuel filter cartridge with a final half-turn. Open fuel stopcock.
5.1.21
Clean the fuel strainer 4 in fuel. Replace if necessary. Refit in the reverse order. Bleed fuel system, see 3.1.4 Check for leaks.
SERVICE AND MAINTENANCE 6.3 Cooling System
6.3.1 Cleaning Intervals The amount of contamination in the cooling system depends on the engine Spilled oil or fuel on the engine increases the risk of contamination. Be especially careful if the engine is used in dusty environments. Serious contamination can occur, for example: - on construction sites where there is a high level or air borne dust. - in harvesting applications where here are high concentrations of chaff and chopped straw in the vicinity of the machine. Because applications vary, cleaning intervals have to be determined from case to case. The cleaning intervals given in the table on the right can be used as a guide.
5.1.22
SERVICE AND MAINTENANCE 6.4 Combustion Air Filter
6.4.1 Cleaning Intervals The amount of dirt in the air cleaner depends on the amount of dust in the air and the size of the air cleaner used. If a high level of dust is anticipated, a cyclone-type precleaner can be fitted to the air cleaner. Cleaning intervals will have to be determined from case to case. If dry-type air cleaners are used, they should be cleaned only in accordance with the service indicator or the service switch. Air cleaner servicing is needed when: - Service indicator the red signal 1 is fully visible when the engine is off. - Service switch the yellow pilot light comes on when the engine is running. After carrying out service work, reset the signal by pressing the button on the service indicator.
6.4.2 Emptying Cyclone Type Precleaner
Undo wing nut 1 and remove cover 2. Remove collector bowl 3 from lower section 4 and empty. Clean leaves, straw and other foreign matter from lower section of precleaner. Reposition collector bowl 3 onto lower section 4, fasten cover 2 in place by tightening wing nut 1.
Never fill collector bowl with oil. Replace collector bowl if damaged.
6.4.3 Cleaning Oil Bath Air Cleaner
Turn engine off and wait about 10 minutes for the oil to drain from filter housing 1. Release snap clips 2 and remove oil cup 3 together with filter element 4. If necessary pry element out with a screwdriver, taking care not to damage the rubber gasket 5. Remove dirty oil and sludge. Clean oil cup. Clean filter element 4 in diesel fuel and allow to drip-dry.
5.1.23
Clean filter housing 1 if very dirty. Inspect and replace rubber gasket 5 and 6 if necessary. Fill oil cup with engine oil up to the mark (arrow) (for viscosity, see 4.1.2). Refit oil cup and element to filter housing and secure with snap rings. Never clean air cleaner with gasoline. Dispose of cold oil in accordance with environmental regulations.
SERVICE AND MAINTENANCE 6.4 Combustion Air Filter
6.4.4 Dry Type Air Cleaner Dust Discharge Valve
Filter Cartridges
Empty dust discharge valve 1 by pressing apart lips of discharge slot as indicated by arrows.
Undo clip fasteners 1.
Clean discharge slot from time to time.
Clean cartridge (replace at least once a year).
Remove any caked dirt by pressing together the upper section of the valve. The amount of dirt in the air cleaner depends on the amount of dust in the air and the size of the air cleaner used. If a high level of dust is anticipated, a cyclone-type precleaner can be fitted to the air cleaner.
Take off hood 2 and remove cartridge 3.
Clean cartridge 3. Blow out from inside out with dry compressed air (max. 5 bar), (or in difficult cases, tap out, taking care not to damage the cartridge, or wash according to manufacturer’s instructions. Through regular removal and replacement, the gaskets on the filter cartridge can become damaged. Check paper filter (light showing through) and gaskets for damage. Replace if necessary. After five cleaner services or after two years at the latest, replace safety cartridge 4 (never clean). To do so: - Undo hex. nut 5 and remove cartridge 4. - Install new cartridge, insert and tighten hex. nut. Cleaning intervals will have to be determined from case to case. Install cartridge 3, replace hood 2 and do up clip fasteners 1.
Never clean filter cartridge with gasoline or hot fluids.
5.1.24
SERVICE AND MAINTENANCE 6.5 Belt Drives
6.5.1 Checking V-Belts
6.5.2 Changing the Fan V-Belt
- Carefully remove the gauge without altering the position of the indicator Replace damaged V-belts. arm 1. After installing new belts, run engine for Read off the value where the black 15 minutes, then check belt tension. indicator arm 1 intersects scale 5 To check the tension of the V-belt, use (arrow). For settings, see 9.1 a tension gauge (see 9.3). - Place indicator arm 1 into gauge. - If necessary, retension belt and - Position gauge on V-belt 2, midway measure again. between the pulleys, with flange 3 on bottom of gauge against the edge of belt. Check tension and change belts - Push slowly on the black pad 4 at only with the engine off. Refit right angles to belt 2 until the spring belt guard, if provided. is heard or felt to trigger. Inspect entire V-belt for damage.
6.5.3 Tensioning Alternator Belts
Loosen bolts 1, 2 and 3. Press alternator 4 outwards in direction of arrow A until correct belt tension is achieved. Retighten bolts 1, 2 and 3.
6.5.4 Changing Alternator Belts
Remove fan V-belts as decribed under 6.5.2 Loosen bolts 1, 2 and 3. Swing alternator 4 inwards in direction of arrow B. Remove V-belts and place on new belt. Swing alternator 4 outwards in direction of arrow A until correct belt tension is achieved. Retighten bolts 1, 2 and 3. Fit fan V-belts.
Only check/tension/replace V-belts Retighten new V-belts after 15 minutes running time. when the engine is at standstill. If 5.1.25 necessary, replace V-belt cover.
To replace, press tension roller 1 using a commercial tool and remove the V-belts. Fit new V-belts.
When new V-belts are fitted check the belt tension after ca. 15 minutes running time.
6.5.5 Checking Warning System
If the V-belt rips, pressure pin 1 of the electrical switch is actuated by the tension roller and an acc oustic or light signal is given. Functional check by pressing in pin 1.
Only carry out a check when the engine is at a standstill.
SERVICE AND MAINTENANCE 6.5 Belt Drives
6.5.6 Tensioning and Changing Air Compressor V-Belts
Unscrew hexagonal bolts 1. Remove outer half of belt pulley 2. If necessary replace the V-belts.
To tighten, remove one or more of the inner intermediate discs 3. Place the removed half of the V-belt pulley 2. Retighten bolt 1. While tightening, simultaneously rotate the engine to prevent the V-belt from being crushed. When new V-belts are fitted, check the belt tension after ca. 15 minutes running time.
6.5.7 Air Compressor Design with Doube V-Belt
Screw off hexagonal nut 1, remove V-belt pulley half 2, V-belt 3 and intermediate disc packet 7. Remove intermediate disc 4, rear V-belt 3, intermediate disc packet 6 and V-belt disc half 5. To tighten, remove on or more of the intermediate discs from packet 6 or 7. Place the removed discs in front of or behind V-belt pulley halves 2, so that the V-belt remains aligned. Always take the same number of discs from each packet.
Fit in the reverse order. While tightening nut 1, the engine must be rotated to prevent the V-belts from being crushed. If a V-belt is worn or damaged, both belts in the set must be replaced. The difference in the length of the new V-belts may not exceed 0.15%. Only check or replace V-belts when the engine is at a standstill. If necessary replace V-belt cover. When new V-belts are fitted, check the belt tension after approx. 15 minutes running time.
5.1.26
SERVICE AND MAINTENANCE 6.6 Adjustments
6.6.1 Checking / Adjusting Valve Clearances
Remove the cylinder head cover. Position crankshaft as per schematic Before adjusting valve clearance, allow engine to cool down for at least 30 minutes. The oil temperature should be below 80°C. Check valve clearance 1 between rocker arm / tappet contact face 2 and valve stem 3 with feeler gauge 6 (there should be only slight resistance when feeler blade is inserted). For permissible valve clearance, see 9.1
Adjust valve clearance if necessary: - Release locknut 4. - Use screwdriver 7 to turn setscrew 5 so that the correct clearance is attained after locknut 4 has been tightened. Check and adjust valve clearance on all remaining cylinders. Replace cylinder head cover (use new gasket if needed).
Only inclined engines are fitted with an additional oil jet for lubrication of the bearing. Any adjustments must be carried out in an authorized specialist workshop.
6.6.1.1 Valve Clearance Adjustments Schematic Crankshaft Position 1: Turn crankshaft until both valves in cylinder 1 overlap (exhaust valve about to close, inlet valve about to open). Adjust clearance of valve marked in black on schematic. Mark respective rocker arm with chalk to show that adjustment has been done.
Crankshaft Position 2: Turn crankshaft one full revolution (360°). Adjust clearance of valves marked in black on schematic.
5.1.27
SERVICE AND MAINTENANCE 6.7 Accessories
6.7.1 Battery 6.7.1.1 Checking Battery and Cable Connectors
Keep battery clean and dry. Undo dirty clamps. Clean terminal posts (+ and - ) and clamps of the battery, grease with acid-free and acid-resistant grease. When reassembling, ensure that clamps make good contact. Turn clamp bolts finger tight.
Remove caps 1. If testers 2 are used, the electrolyte should come up to their base. If testers are not used, the electrolyte level should be 10 15mm above the top of the plates. If necessary, top up with distilled water. Replace caps.
The gasses emitted by the battery are explosive! Keep sparks and naked flames away from the battery. Do not allow battery acid to come into contact with skin or clothing. Wear protective goggles. Do not rest tools on the battery.
5.1.28
Measure the electrolyte density of individual cells with a commercial hydrometer. The hydrometer reading (see table on following page) indicates the state of charge. During measurement, the temperature of the electrolyte should preferably be +20°C.
SERVICE AND MAINTENANCE 6.7 Accessories
6.7.2 Three-Phase Alternator
6.7.3 Lifting Tackle
Never disconnect the cable between battery, alternator and regulator while the engine is running. If, however, it is necessary to start and operate the engine without the battery, disconnect the regulator from the alternator before starting. Be sure not to confuse the battery terminals. Replace defective bulb of the charge pilot lamp immediately. When washing the engine, cover up the alternator and regulator. The habit of touching a lead against the frame to check whether it is live must under no circumstances be used with three-phase electrical systems. In case of electric welding connect ground terminal on the welder directly to the piece being welded.
Always use proper lifting tackle 1 when transporting the engine. After transportation and before commissioning of the engine: Remove transport eyes 2.
Use only the correct lifting tackle.
5.1.29
SERVICE AND MAINTENANCE 6.8 Engine Cleaning
6.8.1 Cleaning the Engine With Compressed Air
Switch off the engine. Remove engine covers, cooling-air hoods. Replace following cleaning and before test run. Cover electrical / electronic components / connections (e.g. alternator, starter, regulator, solenoid). Pass compressed air through the engine, being careful with the cooler and cooling fins (start at the exhaust side). Remove dirt which has been blown into the inner compartment.
With Cold-Cleaning Compound
Switch off the engine. Remove engine covers, cooling-air hoods. Cover electrical / electronic components / connections (e.g. alternator, starter, regulator, solenoid). Spray engine with commercial cold-cleaning compound and leave to work for approx. 10 minutes. Spray engine clean with water jet and if necessary repeat procedure.
With High=Pressure Equipment
Switch off the engine. Remove engine covers, cooling-air hoods. Cover electrical / electronic components / connections (e.g. alternator, starter, regulator, solenoid). Clean engine with steam jet (max. spray pressure 60 bar, max. steam temperature 90°C). Drive the engine warm so that remaining water evaporates.
Drive the engine warm so that remaining water evaporates.
The engine may only be cleaned when it is at a standstill.
5.1.30
SERVICE AND MAINTENANCE 6.9 Additional Maintenance
6.9.1 Checking the Mountings
Cylinder head cover 1 Air-intake pipe 2 Coupling sleeves Exhaust line 3 Engine mounting 4
Test Stage 1: Move speed adjustment lever and shut-off lever to “stop” position. Insert key - Position 0 = no operating voltage Turn key clockwise. - Postion 1 = operating voltage - Pilot light comes on. Press in key and turn further clockwise against the spring pressure. - Position 2 = preheat, hold for approx. 1 minute. - Preheat lamp lights up. Otherwise flame glow plug defective or power interrupted.
6.9.2 Checking the Function of the Heating Pipe
When functioning correctly, the heating pipe heats up via the integrated heating coil when starting the preheating - heating pipe - air intake pipe
Test Stage 2:
6.9.3 Checking the Function of the Flame Glowing System
When functioning correctly, intake pipe 4 heats up in the vicinity of flame glow plug 2 when starting with preheating.
Test Stage 3:
Loosen pipe connection 1.
Loosen pipe connection 1.
Rotate engine with starter, key on switch position 3.
Remove flame glow plug 2.
Fuel must be emitted at loosened pipe connection. Otherwise have the system, solenoid 3, checked by a specialist.
Rotate engine with starter, key in switch postition 3. Fuel must be emitted at flame glow plug 2, replace plug 2 as necessary. Use sealant DEUTZ DW 47 when fitting flame glow plug 2. Refit flame glow plug 2 on fuel line. Keep clear of rotating parts. Collect any leaked fuel and dispose of in an environmentally friendly fashion.
5.1.31
FAULTS, CAUSES AND REMEDIES 7.1 Diagnosis Chart
5.1.32
ENGINE PRESERVATION 8.1
If the engine is to remain idle for an extended period of time, it is necessary to take protective measures to prevent rust formation. The preservative measures described here will protect the engine for up to 6 months. The procedure will have to be reversed before the engine is recommissioned. Anti-corrosion oils to specification: - MIL-L-21260B - TL 9150-037/2 - Nato Code C 640 / 642 Recommended cleansing agent to remove preservatives when recommissioning engine: - Petroleum benzine (hazardous materials class A3)
8.1.1 Preserving Engine Clean engine (with cold cleansing agent if preferred) using high pressure equipment. Run engine until warm, then turn off. Drain engine oil, see 6.1.2 and fill with anti-corrosion oil. If necessary, clean oil bath cleaner, see 6.4.3, and fill with anti-corrosion oil. Drain fuel from tank. Make up a mixture of 90% diesel fuel and 10% anti-corrosion oil, and refill fuel tank. Run engine for about 10 minutes. Turn engine off. Turn engine over manually several times to preserve the cylinders and combustion chamber. When rotating with starter, place shut-off lever in stop position. Remove V-belts and store dry in wrapped condition. Spray grooves on V-belts pulleys with anti-corrosion spray.
8.1.2 Removing Engine Preservatives Remove anti-corrosion agent from grooves in V-belt pulleys. Install V-belts. Retension after brief operation if necessary, see 6.5 Remove plugs from intake port and exhaust port. Set the engine in operation.
5.1.33
TECHNICAL SPECIFICATIONS
9.1 Engine Specifications and Settings
5.1.34
TECHNICAL SPECIFICATIONS
9.1 Engine Specifications and Settings
5.1.35
TECHNICAL SPECIFICATIONS 9.2 Torque Wrench Settings
TECHNICAL SPECIFICATIONS 9.3 Tools
The V-belt tension gauge can be obtained under order number 8115 from: COMPANY WILBÄR Postfach 14 05 80 D-42826 Remscheid
5.1.36
ORDERING SPARE PARTS Order information Please specify the following information when ordering original DEUTZ parts. - Engine no. - Ident. no. - Quantity
Document structure
-
The picture diagrams in this spare parts list are sorted according to engine assembly groups.
-
Each section is preceded by an overview of the assembly groups.
-
The ident. no. 08/23 us made up of the assembly group (e.g. 08) and item number (e.g. 23).
5.1.37
ENGINE MAINTENANCE SCHEDULE McL 42 HD
DATE/HRS
SERVICE PERFORMED
5.1.38
BY
NOTES
McL 42 HD
5.1.39
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
DETAIL
PAGE
MACHINE SPLIT COUPLING (PUMP & GEARBOX) HYDRAULIC PUMP COUPLING DOG PLATE THRUST CYLINDER HYDRAULIC CLUTCH PUMP SETTINGS AND ADJUSTMENTS MAIN THRUST VALVE ADJUSTMENT
7.1.1 7.2.1 7.3.1 7.4.1 7.5.1 7.6.1 7.7.0 7.8.0
7.1.0
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
WARNING:
DANGER:
Moving parts. Keep all guards in place. Shut down engine before service or maintenance. Being caught in machinery could cause serious injury.
Crushing weight will cause serious injury. Place machine on solid surface to prevent rollover or falling.
CAUTION:
CAUTION:
Do not modify this machine. Use only authorized McLaughlin repair parts. Failure to comply may result in serious injury. Service this equipment according with maintenance instructions in this manual.
High Pressure. Leaking hydraulic fluid under pressure may penetrate and cause serious injury. Check for leaks with cardboard. Relieve pressure before working on any system.
7.1 Machine Split Instructions 1a
A. Removing the Carriage Important Note: If the jacking station is to be removed from the track, then do the following, in sequence, before removing, the carriage: 1.) Fully retract dog pins. 2.) Close dog pin valve while pins are retracted. 3.) Turn OFF dog pin switch. 4.) Fully retract thrust cylinders. 1.) With the engine OFF, and the key in the OFF position, cycle the thrust valve handle up and down a few times to release any pressure in the system. Disconnect all hydraulic and electrical connections. There are a total of four hydraulic connections and one electrical connection. Use Figures 1 a-e to identify connection points. • Main Thrust Valve - 2 hydraulic connec tions. (Figure 1a) • Track Brake - 1 hydraulic connection (Figure 1b) • Dog Plate - 1 hydraulic connection, 1 electrical connection. (Figure 1c) Install all caps on disconnects.
1b
1c
2.) There are eight bolted connection between the jacking station and carriage. Four bolts fasten vertically and four bolts fasten horizontally. Loosen and rotate the carriage hold down bolts out of their carriage slots.. (Figure 1d) 3.) Use the four lifting eyes on the roll bars to raise the carriage out of the jacking station. DO NOT LIFT THE CARRIAGE AT ANY OTHER POINT EXCEPT BY ALL FOUR LIFTING EYES. The weight of the
7.1.1
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
carriage is not evenly distributed. Use caution when lifting. Make sure all hoses and wires are free from machine components before separating the machine. Place the carriage on a flat and stable surface.
1d
B. Removing the Casing Pusher 1.) The casing pusher has four bolted connections. Loosen, but do not remove the bolts. Rotate the bolts out of the carriage slots. 2.) The casing pusher must be moved far enough horizontally in order to clear the chuck before it can be lifted vertically from the machine.
1e
C. Removing the Jacking Station from Track 1.) The procedures from “Section I - Important Note” must be followed prior to removing the jacking station from the track. 2.) Raise and pin the track hold downs in the retracted position. (Figure 1e) 3.) Use the four lifting eyes in the jacking station to lift the jacking station out of the track. The weight of the jacking station is not evenly distributed. Use caution when lifting. 4.) Place the jacking station on a flat and stable surface. D. Assemble Carriage to Jacking Station 1.) Verify all hoses and wires are free from being pinched or crushed when placing the carriage into the jacking station. Be careful not to damage machine components when placing the carriage. 2.) Once the carriage is resting in the jacking station, fasten the four horizontal bolts first. This will secure the carriage front plate against the jacking station’s thrust wall. Now fasten the four vertical bolts. 3.) Make the four hydraulic and one electrical connections. 4.) Fully open dog pin valve. 5.) Lower and pin the track hold down in the engaged position.
7.1.2
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
7.2 Coupling Instructions Tools Required: - 5/8” hex bit socket and ratchet - 1 1/8” socket or wrench - 3/16” Allen-head T-handle wrench - McLaughlin Tool #4810321 1. REMOVAL Remove the coupling guard from mounted position on the transmission. Remove the two bolts that fasten the coupling hub to the coupling. Loosen the set screw over the key in the coupling hub. Slide the coupling hub up the input adapter shaft to create enough clear ance for removing the coupling center member. Next, fit McLaughlin tool #4810321 onto the companion flange. Use this tool to prevent the transmis sion form rotating when removing the last two bolts of the coupling center member.
II. INSTALLATION Install the coupling hub onto the input adapter shaft. Install the coupling center member into its’ respective pilot holes on the coupling adapter plate. Fit McLaughlin tool #4810321 onto the companion flange and then tighten the two botls to 225 ft-lbs. Slide coupling hub onto the pilots of the coupling center member. Tighten the two bolts to 225 ft.lbs. Tighten the set screw over the key. Install the coupling guard.
7.2.1
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
7.3 Hydraulic Pump Coupling Assembly
Alignment Loosen, but do not remove the 4 screws that attach the pump adapter plate to the pump mount. Adjust the pump plate until the nylon sleeve on the coupling slides freely. Tighten the 4 screws. (Fig. 1-c) Disassembly/Assembly D1. Remove the screw for the pump and pull the pump out of the adapter plate. Do not remove the 4 screws which attach the adapter plate to the pump mount. D2. Loosen the coupling cross-clamp and remove the coupling from the pump shaft.
A1. Pilot the adapter plate to the engine crankshaft pulley. Make sure that all hoses are properly lined up and that the adapter is sitting flush against the pulley. Apply Loctitie #271 to the screws and tighten the screws in an alternating circular pattern. A2. Pilot the coupling hub into the adapter. Make sure that the coupling is sittling properly on the face of the adapter. Apply loctite #271 to the screws andtighting the screws in an alternating pattern. A3. Install the nylon sleeve onto the coupling. A4. Install the pump coupling onto the pump
D3. Remove the nylon sleeve. D4. Remove the screws that attach the coupling hub to the adapter plate and remove the coupling hub.
Adapter Plate
Pump Coupling
Nylon Sleeve
7.3.1
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
Dog Pin Indicator Detail Some items not shown for clarity.
7.4 DOG PLATE Dog Pin Indicators - The dog pin indicator lights should come on when the dog pins are retracted and go off when the dog pins are fully extended. Adjust the switches so the lights give an accurate indication of the dog pin position. Sometimes the dog pin may be in a bind and may not be able to extend fully. Check that the dog pins are working freely before making any adjustments. Make sure that the dog pin valve is open enough (5-6 turns) for the pins to move freely. Dog Pin Indicator Switch Adjustment 1. Extend the dog pins. 2. Remove the top plate on the dog plate cover box. 2. Turn the ignition switch to the “ON” position and note dog pin positions and dog pin indicator lights. 3. The switch brackets allow for adjustment forward and backward, and side to side. Loosen, but do not remove the screws which will allow movement in the required direction for proper switch placement. Note: The switch should be positioned with “DIM A” = 1/4”-3/8” air gap between the switch arm and the hydraulic dog plate cylinder. Refer to the illustration above. 4. Tighten the screws and test the operation by repeatedly extending and retracting the dog pins. Repeat these steps if further adjustments are necessary.
7.4.1
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
Dog Plate Adjustable Valve
Dog Plate Cylinder Replacement D1. Open the dog pin valve completely. D2. Remove the top plate of dog plate box. D3. Disconnect and cap the hydraulic hose at the cylinder swivel fitting. D4. Remove the two screws that attach the cylinder to the dog pins. The dog pins are spring loaded, so there will be pressure on the screws when they are removed. Note: Be careful not to damage machine components still in place, wires, switches, etc. D5. It is recommended that the dog plate be thoroughly cleaned whenever the dog plate cylinder is removed. D6. Remove the dog pins and dog pin springs. Clean the dog pins and remove any rust or corrosion on the pins. Clean any mud or dirt out of the springs. Replace springs if necessary. Clean the dog plate housing. Make sure the dog pins can slide freely in and out by hand, before reassembling. A1. The dog pin has a top and a bottom. The top of the dog pin is determined by the depth of the set screw in the tapped hole. The top of the dog pin has a set screw depth of ~ 5/16”. If this dimension is not correct, adjust the set screw. Remove the set screw and clean off any residual thread lock. Clean the tapped hole in the dog pin. Apply Loctite #243 to the set screw and insert it into the dog pin to the proper depth. Allow the thread lock to cure before reassembling.
7.4.2
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
A2. Insert the dog pin springs into the dog plate. Make sure the springs slide over the center pin and are seated on the stop in the center of the housing. A3. After the dog plate and pins have been cleaned, apply a thin film of oil to the pins and insert them into the dog plate. Do not use grease or heavy oils. These heavier lubricants tend to attract dirt more than lighter oils. A4. Press the dog pins into the housing until the tapped holes in the dog pins are accessable in the slots in the top plate. A5. Put the cylinder screws through the cylinder end lugs and thread the screws into the dog pins. Tighten the screws until they bottom out on the set screws in the dog pins. Once tight, there should be a small gap between the base of the cylinder and the dog plate. The gap keeps the cylinder from pulling the dog pins against the top of the dog plate. Note: The cylinder must be positioned properly to match up with the dog pin indicator switches. A6. Connect the hose to the dog plate cylinder swivel fitting. A7. Operate machine and check for leaks. A8. Replace the top plate. Dog Plate Cylinder Seal Kit Replacement D1. Remove cylinder as described in the above section. D2. Remove the swivel fitting and unscrew the threaded cap. NOTE: FLUID UNDER PRESSURE. THERE MAY BE REMAINING HYDRAULIC FUILD IN THE CYLINDER. EXTENDING OR RETRACTING THE CYLINDER CAN FORCE FLUID OUT OF THE CYLINDER. FLUID UNDER PRESSURE CAN CAUSE SERIOUS INJURY. D3. Pull the rod assembly out of the barrrel. D4. Remove the piston from the end of the rod assembly. D5. Remove the threaded cap from the rod assembly. D6 Remove and discard all seals, o-rings, back-up washers and wipers. Visually note the placement and orientation of all seals before removal. A1. Clean all components with brake cleaner and let dry. A2. Refer to the Dog Plate Cylinder Components section of this manual for proper seal placement and orientation. Lube all seals and wipers with a thin coat of oil before assembly. A3. Install the threaded cap onto the rod assembly, note proper orientation. A4. Install the piston onto the rod assembly. A5. Insert the rod assemlby into the barrel. A6. Tighten the threaded cap. A7. Refer to Dog Plate Cylinder Replacement instructions for assemlby procedure.
7.4.3
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
THRUST CYLINDER Removal: D1. Remove the carriage from the jacking station. D2. Disconnect and cap the hydraulic hoses and cylinder ports. D3. Disconnect the hydraulic and electrical connections at the dog plate. D4. Remove the 3 cylinder pins in the dog plate and slide the dog plate away from the cylinders. D5. Remove the cylinder from the jacking station. Note: Be careful not to damage machine components already in place.
Thrust Cylinder Seal Kit Replacement: D1. Remove the rod clevis. D2. Remove the rod-end base plate. D3. Unscrew the rod end cap. D4. Pull the rod assembly out of the barrel. D5. Remove the piston from the end of the rod assembly. D6. Remove and discard all seal and wipers. Visually note the placement and orientation of all seals before removal. A1. Clean all components with brake cleaner and let dry. A2. Refer to the Thrust Cylinder Components section of this manual for proper seal placement and orientation and torque requirements for fasteners. Lube all seals with a light coat of oil before assembly. A3. Install the piston on the rod assembly and torque the retaining nut to the proper specifications. A4. Insert the rod assembly into the barrel. A5. Install the rod end cap and torque to the proper specifications. A6. Install the rod end plate and torque screws to the proper specifications. A7. Position the cylinder in the jacking station and reinsert the cylinder pin. A8. Position the dog plate on the cylinders and insert the dog plate cylinder pins. A9. Connect the hoses. A10. Connect the hydraulic and electrical connections at the dog plate. A11. Install the carriage. A12. Operate the machine and check for leaks.
7.5.1
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
7.6 CLUTCH SERVICE Disassemble for Disc Change:
7.6.1
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
Assemble for Disc Change:
7.6.2
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
Disassemble Clutch:
7.6.3
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
Assemble Clutch:
7.6.4
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
7.7 PUMP SETTINGS AND ADJUSTMENTS This machine is equiped with a pressure compensated, hydraulic piston pump with load sense. It has two adjustable settings, Compensator pressure setting and Stand-by pressure setting. Refer to the Specifications and Settings section of this manual for those settings. The case ports are identified by the following marks: Inlet Port (suction) : Right side of pump (facing the front of the machine) Outlet Port (pressure) : Left side of pump (facing the front of the machine) Load Sense Port: Top center of pump, marked “X”. Case Drain Port: Top center of pump, marked “L2”. Gauge Port (system pressure) : Bottom side of pump, marked “M2”.
Stand-by Pressure Adjustment
Compensator Adjustment
Pump Setting Detail
7.7.1
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
Setting the Stand-by Pressure ~ 250-300 psi (17.5 - 20.7 bar) * Remove and cap 2nd system to read only, pop stand-by pressure. The Stand-by pressure setting, is set by adjusting the top set screw on the top-center of the pump case. 1. Install a 0-5000 psi minimum pressure gauge into the gauge port on the pump. 2. Start the engine. The pressure on the gauge is the current stand-by pressure setting. 3. Loosen, but do not remove, the locking set screw in the side of the adjustment housing. 4. Adjust the set screw in the center of the adjustment housing until the desired pressure is acheived. 5. Tighten the locking set screw. 6. Check pressure setting. Setting the Compensator ~ 5000 psi (344.8 bar) The Compensator pressure setting is set by adjusting the bottom set screw on the top-center of the pump case. 1. Install a 0-5000 psi minimum pressure gauge into the gauge port on the pump. 2. Start the engine and retract the cylinders using the manual lever on the thrust control valve. 3. Dead-head the cylinder in the retracted position and the pressure on the gauge is the compensator setting. 4. Loosen, but do not remove, the locking set screw in the side of the adjustment housing. 5. Adjust the set screw in the center of the adjustment housing until the desired pressure is acheived. Dead-head the cylinders and make an adjustment. Release the cylinders and allow the pump to drop to stand-by pressure before making more adjustments. Do not try to adjust the pump all at one time. 6. Tighten the locking set screw. 7. Check pressure setting. NOTE: There are no other adjustable functions on this pump. If the pump requires more service, consult the McLaughlin Manufacturing Co. for pump service and repair instructions.
7.7.2
SERVICE AND REPAIR INSTRUCTIONS McL 42 HD
7.8 Main Thrust Valve Adjustment The main thrust valve has both a manual control lever, and an electric solenoid control. The electrical control portion is covered under the Autobore section. The valve has an adjustable relief valve built in. It is preset at the factory and should not require adjustment in the field. Reference the Components section for valve handles. Relief Valve Adjustment ~ 5100+ psi (351.7 + bar) The relief valve is located just below the instrument panel. Raise the instrument panel to access the relief valve. 1. Install a 0-5000 psi minimum pressure gauge into the gauge port on the pump. 2. Start the engine and confirm that the compensator is set at the proper setting. Note: the relief valve is set 100-200 psi (6.9 - 13.8 bar) above the compensator setting. If the compensator setting is wrong, the relief valve setting will be wrong. 3. Remove the locking cap. 4. Loosen, but do not remove the locking nut on the relief valve. 5. Loosen the relief valve threaded stud 1-2 turns. 6. Run the machine and collapse the thrust cylinders using the manual lever on the valve. 7. Dead-head the cylinders in the retract position and adjust the relief valve until the engine relieves its self. Adjustment of this valve is an audible determination. When the pump goes over relief it continues to pump oil which lugs the engine down. When the pump reaches proper compensator setting and de-strokes, the relief valve is set properly. 8. After the pump de-strokes, turn the relief valve threaded stud 1/4 of a turn and tighten the lock nut. 9. Install the locking cap. 10. Replace and secure the instrument panel.
7.8.1
WARRANTY & RETURN GOODS POLICY LIMITED WARRANTY The Manufacturer warrants its products to be free from defects in material and workmanship for a period of twelve months from the date of shipment from the factory. Hole Hammer pistons, bodies, and nose pieces are warranted to be free from defects in material and workmanship for a period of three years from the date of shipment from the factory. The Manufacturer shall not be responsible for any damage resulting to or caused by its products by reason of installation, improper storage, unauthorized service, alteration of the products, neglect or abuse, or use of the product in a manner inconsistent with its design. This warranty does not extend to any component parts not manufactured by Manufacturer; however, Manufacturer’s warranty herein shall not limit any warranties made by manufacturers of component parts which extend to Buyer. Claims for defects in material and workmanship shall be made in writing to Manufacturer within ten days of discovery of defect. Manufacturer may either send a service representative or have the product returned to its factory at Buyer’s expense for inspection. Upon notification of defect, Manufacturer will issue a return goods authorization number to Buyer. The return goods authorization number must accompany the product returned. If judged by the Manufacturer to be defective in material or workmanship, the product will be replaced or repaired at the option of the manufacturer, free from all charges except authorized transportation. Buyer shall be responsible for all maintenance services consisting of lubrication and cleaning of equipment, replacing expandable parts, making minor adjustments, and performing operating checks, all in accordance with procedures outlined in Manufacturer ’s maintenance literature. THE FOREGOING WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES AND NO REPRESENTATIONS, GUARANTEES, OR WARRANTIES, EXPRESS OR IMPLIED, (INCLUDING BUT NOT LIMITED TO A WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE), ARE MADE BY THE February 8, 2005
MANUFACTURER IN CONNECTION WITH THE MANUFACTURE OR SALE OF ITS PRODUCTS. NO EMPLOYEE, DISTRIBUTOR, OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THIS WARRANTY ON BEHALF OF MANUFACTURER THE REMEDIES OF BUYER SET FORTH HEREIN ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER REMEDIES. THE LIABILITY OF MANUFACTURER WHETHER IN CONTRACT, TORT, UNDER ANY WARRANTY, OR OTHERWISE SHALL NOT EXTEND BEYOND ITS OBLIGATION TO REPAIR OR REPLACE, AT ITS OPTION ANY PRODUCT OR PART FOUND BY MANUFACTURER TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP. MANUFACTURER SHALL NOT BE LIABLE FOR COST OF INSTALLATION AND/OR REMOVAL OR BE RESPONSIBLE FOR DIRECT, INDIRECT, SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY NATURE. GENERAL RETURNS OF MERCHANDISE 1. All returns must be pre-authorized A. Please call our parts department for an RGA number B. Please include RGA number on the outside of box C. Include any required paper work or special instructions D. Items returned without an RGA number will not be accepted 2. All returns are subject to a 20% restock charge. 3. Special items are non-returnable A. Non-stock parts B. Custom parts C. If you are unsure about a parts status when ordering, ask your McLaughlin representative if the item fits on of the above conditions. 4. Items must be returned within thirty days of original order date. 5. Items not returned within 30 days from the date of RGA is issued will not be accepted. 6. The item(s) must be in new condition. Used item(s) are not returnable.
